How To Use This Manual
Copyright Statement
Copyright.© Land Rover Ltd., 2005
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any
form, electronic, mechanical, photocopying, recording or other means, without prior written permission of Land Rover
Ltd., Banbury Road, Lighthorne, Warwick, CV35 0RG
How to use This Manual
This manual covers all aspects necessary in order to service the vehicle effectively.
The manual is structured into five main sections, General Information, Chassis, Powertrain, Electrical and Body and
Paint with each section dealing with a specific part of a vehicle system.
Each of the five main sections contain sub-sections dealing with items which form a part of that specific system.
Pages at the start of the manual list all sections available. Each section has a contents list detailing, where
applicable, Specifications, Description and Operation, Diagnosis and Testing, General Procedures and Repair
Procedures.
Where components need to be removed or disassembled in sequence, each operation in the sequence will be
identified numerically and also graphically in an accompanying illustration.
NOTE:
Workshop Manual Organization
The five main sections, together with the areas which they cover are given below:
z Section 1 - General Information.
z Section 2 - Chassis.
z Section 3 - Powertrain.
z Section 4 - Electrical.
z Section 5 - Body and Paint.
Sub-section numbers appear after the initial section number, for example, Section 412-03 covers air conditioning,
which is part of the electrical section.
In the number given above, the first digit of the number '4' indicates the section i.e. Electrical.
The second and third digits '12' of the number indicate the vehicle system i.e. Air Conditioning.
The last two digits of the number '03' indicate the part of the system covered by the sub-section i.e. Air Conditioning
Compressor.
Published: Feb 8, 2005
Dimensions quoted are to design engineering specifications with service limits quoted, where applicable.
Important Safety Instructions
Safety Notice
Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor
vehicles, as well as the safety of the person doing the work. This manual provides general directions for
accomplishing service and repair work with tested effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill
of the person doing the work. This manual cannot possibly anticipate all such variations and provide advice or
cautions as to each. Accordingly, anyone who departs from the instructions provided in the manual must first
establish that neither personal safety or vehicle integrity is compromised from choices of methods, tools or parts.
Published: Mar 2, 2004
Safety Notice
Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor
vehicles, as well as the safety of the person doing the work. This manual provides general directions for
accomplishing service and repair work with tested effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill
of the person doing the work. This manual cannot possibly anticipate all such variations and provide advice or
cautions as to each. Accordingly, anyone who departs from the instructions provided in the manual must first
establish that neither personal safety or vehicle integrity is compromised from choices of methods, tools or parts.
Published: Mar 2, 2004
General Service Information
Introduction
This manual has been written in a format that is designed to meet the needs of Land Rover technicians worldwide
and to assist them in the efficient repair and maintenance of Land Rover vehicles.
This manual provides descriptions and methods for accomplishing adjustment, service and repair work using tested
and effective procedures. Following these procedures will help ensure product reliability.
Special Tools
The Special Tool(s) Table provided at the beginning of each procedure lists the special tool(s) required to carry out
repair operations within that specific procedure. Wherever possible, illustrations are provided which will assist
technicians in identifying the special tool(s) required and also showing such tool(s) in use.
Special tools may be obtained from the manufacturer, SPX Tools, the addresses of their branches will be found in the
Special Tools Glossary contained within this Section.
Important Safety Instructions
Appropriate service methods and correct repair procedures are essential for the safe and reliable operation of all
motor vehicles as well as ensuring the personal safety of the individual carrying out the work.
This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Any person who
departs from the instructions provided in this manual must first establish that they compromise neither their personal
safety nor the vehicle integrity by their choice of methods, tools or parts.
Individuals who undertake their own repairs should have some skill or training and limit repairs to components which
could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such as
steering, brakes, suspension or supplemental restraint system should be carried out by a Land Rover Dealer. Repairs
to such items should NEVER be attempted by untrained individuals.
Warnings, Cautions and Notes which appear in this manual
As you read through this manual, you will come across Warnings, Cautions and Notes. A Warning, Caution or Note is
placed at the beginning of a series of steps. If the warning, caution or note only applies to one step, it is placed at the
beginning of the specific step after the step number.
Warnings, Cautions and Notes have the following meanings:
Warning: Procedures which must be followed to avoid the possibility of personal injury.
Caution: Calls attention to procedures which must be followed to avoid damage to components.
Note: Gives helpful information.
References
References to the Left Hand (LH) or Right Hand (RH) side given in this manual are made when viewing the vehicle or
unit from the rear.
Fault Diagnostic Equipment
The vehicle is equipped with a number of electronic control systems to provide optimum performance of the vehicle's
systems.
Diagnostic Equipment (T4) is available and must be used where specified. The use of this equipment will assist with
the fault diagnostic abilities of the Dealer workshop. In particular, the equipment can be used to interrogate the
electronic systems for diagnosis of faults which may become evident during the life of the vehicle.
This manual is produced as a reference source to supplement T4.
Published: Feb 17, 2005
Introduction
This manual has been written in a format that is designed to meet the needs of Land Rover technicians worldwide
and to assist them in the efficient repair and maintenance of Land Rover vehicles.
This manual provides descriptions and methods for accomplishing adjustment, service and repair work using tested
and effective procedures. Following these procedures will help ensure product reliability.
Special Tools
The Special Tool(s) Table provided at the beginning of each procedure lists the special tool(s) required to carry out
repair operations within that specific procedure. Wherever possible, illustrations are provided which will assist
technicians in identifying the special tool(s) required and also showing such tool(s) in use.
Special tools may be obtained from the manufacturer, SPX Tools, the addresses of their branches will be found in the
Special Tools Glossary contained within this Section.
Important Safety Instructions
Appropriate service methods and correct repair procedures are essential for the safe and reliable operation of all
motor vehicles as well as ensuring the personal safety of the individual carrying out the work.
This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Any person who
departs from the instructions provided in this manual must first establish that they compromise neither their personal
safety nor the vehicle integrity by their choice of methods, tools or parts.
Individuals who undertake their own repairs should have some skill or training and limit repairs to components which
could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such as
steering, brakes, suspension or supplemental restraint system should be carried out by a Land Rover Dealer. Repairs
to such items should NEVER be attempted by untrained individuals.
Warnings, Cautions and Notes which appear in this manual
As you read through this manual, you will come across Warnings, Cautions and Notes. A Warning, Caution or Note is
placed at the beginning of a series of steps. If the warning, caution or note only applies to one step, it is placed at the
beginning of the specific step after the step number.
Warnings, Cautions and Notes have the following meanings:
Warning: Procedures which must be followed to avoid the possibility of personal injury.
Caution: Calls attention to procedures which must be followed to avoid damage to components.
Note: Gives helpful information.
References
References to the Left Hand (LH) or Right Hand (RH) side given in this manual are made when viewing the vehicle or
unit from the rear.
Fault Diagnostic Equipment
The vehicle is equipped with a number of electronic control systems to provide optimum performance of the vehicle's
systems.
Diagnostic Equipment (T4) is available and must be used where specified. The use of this equipment will assist with
the fault diagnostic abilities of the Dealer workshop. In particular, the equipment can be used to interrogate the
electronic systems for diagnosis of faults which may become evident during the life of the vehicle.
This manual is produced as a reference source to supplement T4.
Published: Feb 17, 2005
Features of the equipment include:
a. Fully upgradeable support for the technician
b. Structured diagnostics to accommodate all skill levels
c. Direct print-out of screen information and test results
Testing the vehicle
Operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work
is inspected and tested after completion and if necessary, a road test of the vehicle is carried out, particularly where
safety related items are concerned.
Repairs and Replacement Parts
Land Rover parts are manufactured to the same exacting standards as the original factory fitted components. For this
reason, it is essential that only genuine Land Rover parts are used during maintenance or repair.
Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and
accessories.
Safety features and corrosion prevention treatments embodied in the vehicle may be impaired if other than Land
Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to manufacturer's
specification. Torque wrench setting figures, where given, must be adhered to and locking devices, where specified
must be used. If the efficiency of a locking device is impaired during removal it must be replaced.
Owners purchasing accessories whilst travelling abroad must ensure that the accessory and its fitted location on the
vehicle conform to legal requirements.
The terms of the vehicle warranty may be invalidated by the fitting of parts other than those recommended by Land
Rover.
NOTE:
All Land Rover recommended parts have the full backing of the vehicle warranty.
Land Rover Dealers are obliged to supply only Land Rover recommended parts.
Specifications
Land Rover are constantly seeking to improve the specification, design and production of their vehicles and
alterations take place accordingly. Whilst every effort is made to ensure the accuracy of this Manual, it should not be
regarded as an infallible guide to current specifications of any particular vehicle.
This Manual does not constitute an offer for sale of any particular vehicle. Land Rover dealers are not agents of Land
Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.
The fitting of non-approved Land Rover parts and accessories or the carrying out of non-approved alterations
or conversions may be dangerous. Any of the foregoing could affect the safety of the vehicle and occupants;
also, the terms and conditions of the vehicle warranty may also be invalidated .
a. Fully upgradeable support for the technician
b. Structured diagnostics to accommodate all skill levels
c. Direct print-out of screen information and test results
Testing the vehicle
Operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work
is inspected and tested after completion and if necessary, a road test of the vehicle is carried out, particularly where
safety related items are concerned.
Repairs and Replacement Parts
Land Rover parts are manufactured to the same exacting standards as the original factory fitted components. For this
reason, it is essential that only genuine Land Rover parts are used during maintenance or repair.
Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and
accessories.
Safety features and corrosion prevention treatments embodied in the vehicle may be impaired if other than Land
Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to manufacturer's
specification. Torque wrench setting figures, where given, must be adhered to and locking devices, where specified
must be used. If the efficiency of a locking device is impaired during removal it must be replaced.
Owners purchasing accessories whilst travelling abroad must ensure that the accessory and its fitted location on the
vehicle conform to legal requirements.
The terms of the vehicle warranty may be invalidated by the fitting of parts other than those recommended by Land
Rover.
NOTE:
All Land Rover recommended parts have the full backing of the vehicle warranty.
Land Rover Dealers are obliged to supply only Land Rover recommended parts.
Specifications
Land Rover are constantly seeking to improve the specification, design and production of their vehicles and
alterations take place accordingly. Whilst every effort is made to ensure the accuracy of this Manual, it should not be
regarded as an infallible guide to current specifications of any particular vehicle.
This Manual does not constitute an offer for sale of any particular vehicle. Land Rover dealers are not agents of Land
Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.
The fitting of non-approved Land Rover parts and accessories or the carrying out of non-approved alterations
or conversions may be dangerous. Any of the foregoing could affect the safety of the vehicle and occupants;
also, the terms and conditions of the vehicle warranty may also be invalidated .
Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always make sure that:
z Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle
moving forwards or backwards.
z Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
z If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust
fumes.
z There is adequate room to raise the vehicle and remove the wheels, if necessary.
z Fender covers are always installed if any work is to be carried out in the engine compartment.
z Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the
vehicle is raised.
z If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.
Battery - General
Jump Starting a Vehicle
z Always make sure that the jumper cables are adequate for the task.
z Always make sure that the slave battery is of the same voltage (12 volts) as the vehicle battery. The batteries
must be connected in parallel.
z Make sure that the battery terminals of both batteries are fully tightened.
z Where another vehicle is used to jump start a disabled vehicle, make sure that the two vehicles are not
Published: Jun 30, 2008
CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to
prevent the possibility of a surge of current causing damage to the internal components of the generator.
WARNING: It is essential that a period of 10 minutes elapses after the battery is disconnected before
any work is undertaken on any part of the SRS system.
CAUTION: Prior to carrying out any procedures which involve disconnecting/ or connecting the
battery, refer to the Electrical Section of this manual - Battery disconnection/connection. For additional
information, refer to Battery (414-01 Battery, Mounting and Cables)
CAUTION: A discharged battery condition may have been caused by an electrical short circuit. If
this condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are
switched off. This can cause arcing when the jumper cables are connected.
CAUTION: While it is not recommended that a vehicle is jump started, it is recognized that this may
occasionally be the only practical way to mobilize a vehicle. Reference should be made to the following.
CAUTION: It is advisable not to use starter/charger sets for jump starting but if this is unavoidable,
make sure that the sets are not used in the 'START' mode.
Vehicle in Workshop
When working on a vehicle in the workshop always make sure that:
z Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle
moving forwards or backwards.
z Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
z If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust
fumes.
z There is adequate room to raise the vehicle and remove the wheels, if necessary.
z Fender covers are always installed if any work is to be carried out in the engine compartment.
z Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the
vehicle is raised.
z If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.
Battery - General
Jump Starting a Vehicle
z Always make sure that the jumper cables are adequate for the task.
z Always make sure that the slave battery is of the same voltage (12 volts) as the vehicle battery. The batteries
must be connected in parallel.
z Make sure that the battery terminals of both batteries are fully tightened.
z Where another vehicle is used to jump start a disabled vehicle, make sure that the two vehicles are not
Published: Jun 30, 2008
CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to
prevent the possibility of a surge of current causing damage to the internal components of the generator.
WARNING: It is essential that a period of 10 minutes elapses after the battery is disconnected before
any work is undertaken on any part of the SRS system.
CAUTION: Prior to carrying out any procedures which involve disconnecting/ or connecting the
battery, refer to the Electrical Section of this manual - Battery disconnection/connection. For additional
information, refer to Battery (414-01 Battery, Mounting and Cables)
CAUTION: A discharged battery condition may have been caused by an electrical short circuit. If
this condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are
switched off. This can cause arcing when the jumper cables are connected.
CAUTION: While it is not recommended that a vehicle is jump started, it is recognized that this may
occasionally be the only practical way to mobilize a vehicle. Reference should be made to the following.
CAUTION: It is advisable not to use starter/charger sets for jump starting but if this is unavoidable,
make sure that the sets are not used in the 'START' mode.
touching.
z It is advisable that the engine of the donor vehicle is switched off during jump starting; take care to make sure
that the battery of the donor vehicle does not also become discharged.
z Always make sure that switchable electric circuits are OFF before connecting jump cables. This reduces the
risk of arcing occurring when the final connection is made.
Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and
recharged as soon as possible to avoid permanent damage.
Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in
excess of eight hours continuous driving with no additional loads placed on the battery.
Trickle charging (defined as voltages <16 volts) may be carried out with the battery connected. Make sure that the
battery terminals are fully tightened prior to trickle charging.
Towing the Vehicle
Towing the vehicle on all four wheels with driver operating steering and brakes.
Turn ignition key to position 1 to release steering lock.
Select neutral in main gearbox and transfer box.
Secure tow rope, chain or cable to front towing eyes.
Release the parking brake.
Rear suspended tow by breakdown vehicle
If the front axle is to be trailed turn ignition key to position 1 to release steering lock.
Select neutral in main gearbox and transfer box.
Transporting the vehicle by trailer
Lashing/towing eyes are provided on front and rear of the chassis side members to facilitate the securing of the
vehicle to a trailer or other means of transportation.
Position vehicle on trailer and apply the parking brake. Select neutral in main gearbox.
General installation Instructions
CAUTION: Boost charging may only be carried out with the battery disconnected from the vehicle.
CAUTION: The vehicle has permanent four-wheel drive. The following towing instructions must be
adhered to:
CAUTION: The brake servo and power assisted steering system will not be functional without the
engine running. Greater pedal pressure will be required to apply the brakes and the steering system will
require greater effort to turn the front road wheels. The vehicle tow connection should be used only in
normal conditions, 'snatch' recovery should be avoided.
CAUTION: The steering wheel and/or linkage must be secured in the straight ahead position. Do not
use the steering lock mechanism for this purpose.
CAUTION: Underbody components must not be used as lashing points.
z It is advisable that the engine of the donor vehicle is switched off during jump starting; take care to make sure
that the battery of the donor vehicle does not also become discharged.
z Always make sure that switchable electric circuits are OFF before connecting jump cables. This reduces the
risk of arcing occurring when the final connection is made.
Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and
recharged as soon as possible to avoid permanent damage.
Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in
excess of eight hours continuous driving with no additional loads placed on the battery.
Trickle charging (defined as voltages <16 volts) may be carried out with the battery connected. Make sure that the
battery terminals are fully tightened prior to trickle charging.
Towing the Vehicle
Towing the vehicle on all four wheels with driver operating steering and brakes.
Turn ignition key to position 1 to release steering lock.
Select neutral in main gearbox and transfer box.
Secure tow rope, chain or cable to front towing eyes.
Release the parking brake.
Rear suspended tow by breakdown vehicle
If the front axle is to be trailed turn ignition key to position 1 to release steering lock.
Select neutral in main gearbox and transfer box.
Transporting the vehicle by trailer
Lashing/towing eyes are provided on front and rear of the chassis side members to facilitate the securing of the
vehicle to a trailer or other means of transportation.
Position vehicle on trailer and apply the parking brake. Select neutral in main gearbox.
General installation Instructions
CAUTION: Boost charging may only be carried out with the battery disconnected from the vehicle.
CAUTION: The vehicle has permanent four-wheel drive. The following towing instructions must be
adhered to:
CAUTION: The brake servo and power assisted steering system will not be functional without the
engine running. Greater pedal pressure will be required to apply the brakes and the steering system will
require greater effort to turn the front road wheels. The vehicle tow connection should be used only in
normal conditions, 'snatch' recovery should be avoided.
CAUTION: The steering wheel and/or linkage must be secured in the straight ahead position. Do not
use the steering lock mechanism for this purpose.
CAUTION: Underbody components must not be used as lashing points.
Component removal
Whenever possible, clean components and the surrounding area before removal.
z Blank off openings exposed by component removal.
z Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or caps.
z Seal open ends of exposed oilways using suitable tapered hardwood plugs or conspicuous plastic plugs.
z Immediately a component is removed, place it in a suitable container; use a separate container for each
component and its associated parts.
z Clean bench and provide marking materials, labels and containers before disassembling components.
Disassembling
Observe scrupulous cleanliness when disassembling components, particularly when brake, fuel, air suspension or
hydraulic system parts are disassembled. A particle of dirt or cloth fragment could cause a serious malfunction if
trapped in these systems.
z Blow out all tapped holes, crevices, oilways and fluid passages with dry, compressed air.
z Use suitable marker ink to identify mating parts, do not use a scriber or centre punch as they could initiate
cracks or distortion.
z Wire or tape mating parts together where necessary to prevent accidental interchange.
z Suitably identify parts which are to be renewed and to those parts requiring further inspection. Keep these
parts separate.
z To make sure that the correct replacement part has been obtained, do not discard a part due for renewal until
after comparing it with the new part.
Cleaning components
Always use cleaning agents which are suitable for the work being undertaken and the components being cleaned.
NEVER use gasoline (petrol) as a cleaning agent (degreaser). Always make sure that the component being cleaned
is compatible with the cleaning agent.
Always follow the manufacturer's instructions regarding the use of cleaning agents and make sure that the
environment in which the work is being undertaken is suitable. See Health and Safety Precautions for further
information regarding cleaning.
General inspection of components
All components should be inspected for wear or damage before reassembling.
z Always make sure that component to be inspected is clean and free from oil or grease.
z When a component is to be checked dimensionally against design specified values, use the appropriate
measuring equipment i.e. micrometers, verniers, surface plates, dial test indicators (DTI).
z Always make sure that all measuring equipment is correctly calibrated before use.
z Reject a component which is not within specified values/limits or if it appears to be damaged.
z A component may be re-installed if dimensions obtained during checking are at the maximum tolerance limit
and it is in an undamaged condition.
z Bearing journal clearances should be checked where necessary using Plastigage.
z Gaskets, seals and O-ring seals are to be re-used unless damaged.
Joints and Joint Faces
All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and install
O-rings using the fingers only.
Use gasket removal spray and/or plastic scrapers to remove traces of old gasket.
WARNING: Suitable eye protection must be worn.
CAUTION: DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.
Whenever possible, clean components and the surrounding area before removal.
z Blank off openings exposed by component removal.
z Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or caps.
z Seal open ends of exposed oilways using suitable tapered hardwood plugs or conspicuous plastic plugs.
z Immediately a component is removed, place it in a suitable container; use a separate container for each
component and its associated parts.
z Clean bench and provide marking materials, labels and containers before disassembling components.
Disassembling
Observe scrupulous cleanliness when disassembling components, particularly when brake, fuel, air suspension or
hydraulic system parts are disassembled. A particle of dirt or cloth fragment could cause a serious malfunction if
trapped in these systems.
z Blow out all tapped holes, crevices, oilways and fluid passages with dry, compressed air.
z Use suitable marker ink to identify mating parts, do not use a scriber or centre punch as they could initiate
cracks or distortion.
z Wire or tape mating parts together where necessary to prevent accidental interchange.
z Suitably identify parts which are to be renewed and to those parts requiring further inspection. Keep these
parts separate.
z To make sure that the correct replacement part has been obtained, do not discard a part due for renewal until
after comparing it with the new part.
Cleaning components
Always use cleaning agents which are suitable for the work being undertaken and the components being cleaned.
NEVER use gasoline (petrol) as a cleaning agent (degreaser). Always make sure that the component being cleaned
is compatible with the cleaning agent.
Always follow the manufacturer's instructions regarding the use of cleaning agents and make sure that the
environment in which the work is being undertaken is suitable. See Health and Safety Precautions for further
information regarding cleaning.
General inspection of components
All components should be inspected for wear or damage before reassembling.
z Always make sure that component to be inspected is clean and free from oil or grease.
z When a component is to be checked dimensionally against design specified values, use the appropriate
measuring equipment i.e. micrometers, verniers, surface plates, dial test indicators (DTI).
z Always make sure that all measuring equipment is correctly calibrated before use.
z Reject a component which is not within specified values/limits or if it appears to be damaged.
z A component may be re-installed if dimensions obtained during checking are at the maximum tolerance limit
and it is in an undamaged condition.
z Bearing journal clearances should be checked where necessary using Plastigage.
z Gaskets, seals and O-ring seals are to be re-used unless damaged.
Joints and Joint Faces
All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and install
O-rings using the fingers only.
Use gasket removal spray and/or plastic scrapers to remove traces of old gasket.
WARNING: Suitable eye protection must be worn.
CAUTION: DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.
Many joints use sealants instead of gaskets as the sealing medium. Where this is the case, the sealant together with
its part number will be found listed in the relevant repair operation and also in the sealants table.
Do not allow sealant to enter tapped holes or oilways.
Locking Devices
Always replace locking devices with one of the same design and of the correct size.
Tab washers
Always release locking tabs before loosening fixings, do not re-use tab washers.
Locknuts
Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.
Roll pins
Always install new roll pins of the correct size.
Circlips
Always install new circlips ensuring that they are of the correct size for the groove.
Woodruff keys
Woodruff keys may be re-used provided there is no indication of wear or distortion.
Remove any burrs from edges of keyways using a fine file.
Split pins
Never attempt to straighten and re-use a split pin, always make sure that replacement pins are of the correct size for
the hole in which they are to be installed.
Screw Threads
z Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads
with a tap or die impairs the strength and install of the threads and is not recommended.
NOTE:
z Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be re-used.
New bolts having the same part number as the original must always be installed. When nuts or bolts are to be
discarded, the repair operation and relevant torque chart will include an instruction to that effect. Do not use
proprietary thread locking agents as they may not meet the specification required. See also Encapsulated
('Patched') Bolts and Screws.
z Always make sure that replacement nuts and bolts are at least equal in strength to those that they are
replacing. Castellated nuts must not be loosened to accept a split pin except in recommended cases when
this forms part of an adjustment.
CAUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers,
specified solvents where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as
these may damage the sealing surfaces. Make sure that sealing surfaces are free from oil or grease as
sealants will not adhere properly to contaminated surfaces.
During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap.
Where this is necessary, the instruction to do so will appear in the relevant operation and it is essential that a
tap of the correct size and thread is used.
its part number will be found listed in the relevant repair operation and also in the sealants table.
Do not allow sealant to enter tapped holes or oilways.
Locking Devices
Always replace locking devices with one of the same design and of the correct size.
Tab washers
Always release locking tabs before loosening fixings, do not re-use tab washers.
Locknuts
Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.
Roll pins
Always install new roll pins of the correct size.
Circlips
Always install new circlips ensuring that they are of the correct size for the groove.
Woodruff keys
Woodruff keys may be re-used provided there is no indication of wear or distortion.
Remove any burrs from edges of keyways using a fine file.
Split pins
Never attempt to straighten and re-use a split pin, always make sure that replacement pins are of the correct size for
the hole in which they are to be installed.
Screw Threads
z Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads
with a tap or die impairs the strength and install of the threads and is not recommended.
NOTE:
z Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be re-used.
New bolts having the same part number as the original must always be installed. When nuts or bolts are to be
discarded, the repair operation and relevant torque chart will include an instruction to that effect. Do not use
proprietary thread locking agents as they may not meet the specification required. See also Encapsulated
('Patched') Bolts and Screws.
z Always make sure that replacement nuts and bolts are at least equal in strength to those that they are
replacing. Castellated nuts must not be loosened to accept a split pin except in recommended cases when
this forms part of an adjustment.
CAUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers,
specified solvents where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as
these may damage the sealing surfaces. Make sure that sealing surfaces are free from oil or grease as
sealants will not adhere properly to contaminated surfaces.
During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap.
Where this is necessary, the instruction to do so will appear in the relevant operation and it is essential that a
tap of the correct size and thread is used.
z Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud
can split the housing and also give a false torque reading.
z Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a
false torque reading.
z Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of
components or faulty sealing of joints will result if the sequences are not followed. Where an instruction is
given to tighten in stages, these stages must be adhered to; do not attempt to combine stages particularly
where certain stages involve tightening by degrees.
z To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the
specified torque figure.
z Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.
Where it is stated that bolts and screws may be re-used, the following procedures must be carried out:
z Check that threads are undamaged.
z Remove all traces of locking agent from the threads.
z Make sure that threads are clean and free from oil or grease.
z Apply the specified locking agent to the bolt threads.
Bolt and Nut Identification
An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols
ISO M or M embossed or indented on top of the bolt head.
In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols indicating the
strength grade e.g. 8.8, 10.9, 12.9, 14.9. Alternatively, some bolts and screws have the M and strength grade symbol
stamped on the flats of the hexagon.
Encapsulated ('Patched') bolts and screws
Encapsulated ('patched') bolts and screws have a thread locking agent applied to the threads during manufacture.
Most thread locking agents are coloured, the band of colour extending for 360° around the thread. Some locking
agents however, are neutral in colour and may not be so easily identified apart from a slightly darker area of thread
where the locking agent has been applied. The locking agent is released and activated by the tightening process and
is then chemically cured to provide the locking action.
CAUTION: DO NOT use a wire brush; take care that threads are not damaged.
can split the housing and also give a false torque reading.
z Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a
false torque reading.
z Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of
components or faulty sealing of joints will result if the sequences are not followed. Where an instruction is
given to tighten in stages, these stages must be adhered to; do not attempt to combine stages particularly
where certain stages involve tightening by degrees.
z To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the
specified torque figure.
z Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.
Where it is stated that bolts and screws may be re-used, the following procedures must be carried out:
z Check that threads are undamaged.
z Remove all traces of locking agent from the threads.
z Make sure that threads are clean and free from oil or grease.
z Apply the specified locking agent to the bolt threads.
Bolt and Nut Identification
An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols
ISO M or M embossed or indented on top of the bolt head.
In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols indicating the
strength grade e.g. 8.8, 10.9, 12.9, 14.9. Alternatively, some bolts and screws have the M and strength grade symbol
stamped on the flats of the hexagon.
Encapsulated ('Patched') bolts and screws
Encapsulated ('patched') bolts and screws have a thread locking agent applied to the threads during manufacture.
Most thread locking agents are coloured, the band of colour extending for 360° around the thread. Some locking
agents however, are neutral in colour and may not be so easily identified apart from a slightly darker area of thread
where the locking agent has been applied. The locking agent is released and activated by the tightening process and
is then chemically cured to provide the locking action.
CAUTION: DO NOT use a wire brush; take care that threads are not damaged.
Self-locking bolts and screws
Unless stated in a specific repair procedure, self-locking bolts and screws i.e. nylon patched or trilobular thread can
be re-used provided that resistance is felt when the locking portion enters the female thread.
Nylon patched bolts and screws have a locking agent either applied to, or inserted in the threaded portion. They are
identified by the presence of a coloured section of thread extending approximately 180° around the thread or by a
coloured plug inserted into the bolt.
Trilobular bolts have a special thread form which creates a slight interference with the thread of the hole or nut into
which it is screwed.
Trilobular bolts should not be used as a substitute for patched bolts.
Nut identification
A nut with an ISO metric thread is marked on one face or one of the hexagonal flats with the strength grade symbol 8,
12, 14. Some nuts with the strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the
hexagonal flat opposite the strength grade marking.
A clock face system is sometimes used as an alternative method of indicating the strength grade. The external
chamfers or a face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate
the strength grade.
A dot is used to locate the 12 o'clock position and a dash to indicate the strength grade. If the grade is above 12, two
dots identify the 12 o'clock position.
When tightening a slotted or castellated nut, never loosen it to insert a split pin except where specified as part of an
adjustment procedure. If difficulty is experienced in correctly positioning the slot, alternative washers or nuts should
be selected.
Where a nut is tightened to adjust or maintain bearing pre-load, the tightening procedure must be adhered to.
Self-locking nuts
Unless stated otherwise, self-locking nuts once removed must be discarded and new nuts of the same type and
strength grade installed.
CAUTION: Do Not re-use self-locking fasteners in critical locations e.g. drive plates/flywheel or
engine bearings. Do not install non self-locking fasteners where a self-locking fastener is specified.
Unless stated in a specific repair procedure, self-locking bolts and screws i.e. nylon patched or trilobular thread can
be re-used provided that resistance is felt when the locking portion enters the female thread.
Nylon patched bolts and screws have a locking agent either applied to, or inserted in the threaded portion. They are
identified by the presence of a coloured section of thread extending approximately 180° around the thread or by a
coloured plug inserted into the bolt.
Trilobular bolts have a special thread form which creates a slight interference with the thread of the hole or nut into
which it is screwed.
Trilobular bolts should not be used as a substitute for patched bolts.
Nut identification
A nut with an ISO metric thread is marked on one face or one of the hexagonal flats with the strength grade symbol 8,
12, 14. Some nuts with the strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the
hexagonal flat opposite the strength grade marking.
A clock face system is sometimes used as an alternative method of indicating the strength grade. The external
chamfers or a face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate
the strength grade.
A dot is used to locate the 12 o'clock position and a dash to indicate the strength grade. If the grade is above 12, two
dots identify the 12 o'clock position.
When tightening a slotted or castellated nut, never loosen it to insert a split pin except where specified as part of an
adjustment procedure. If difficulty is experienced in correctly positioning the slot, alternative washers or nuts should
be selected.
Where a nut is tightened to adjust or maintain bearing pre-load, the tightening procedure must be adhered to.
Self-locking nuts
Unless stated otherwise, self-locking nuts once removed must be discarded and new nuts of the same type and
strength grade installed.
CAUTION: Do Not re-use self-locking fasteners in critical locations e.g. drive plates/flywheel or
engine bearings. Do not install non self-locking fasteners where a self-locking fastener is specified.
Ball and Roller Bearings
When removing and installing bearings, make sure that the following practices are observed to make sure component
serviceability:
z Remove all traces from bearing under inspection by cleaning with a suitable degreasant; maintain absolute
cleanliness throughout operations.
z Conduct a visual inspection for markings on rolling elements, raceways, outer surfaces of outer or inner
surfaces of inner rings. Reject any bearings found to be marked since marking in these areas indicates onset
of wear.
z Hold inner race of bearing between finger and thumb of one hand and rotate outer race to check that it
revolves absolutely smoothly. Repeat holding outer race and rotating inner race. DO NOT spin the bearing.
z Rotate outer ring gently using a reciprocating movement whilst holding inner ring; feel for any check or
obstruction to rotation. Reject bearing if movement is not absolutely smooth.
z Check bearing for blueing or signs of overheating.
z Lubricate bearing with the specified lubricant.
z Inspect bearing surface of shaft and bearing housing for discolouration or other markings which indicate
overheating of bearing or movement between bearing and seating.
z Before installing bearing, make sure that shaft and bearing housing are clean and free from burrs.
z If one bearing of a pair shows signs of wear, overheating etc., it is advisable to replace bearings as a pair
unless it is suspected that one bearing may have been faulty when installed, was installed incorrectly or the
fault arose due to oil seal failure.
z Never reinstall a bearing unless it is in a fully serviceable condition.
z When installing a bearing to a shaft, only apply force to the inner ring of the bearing. When installing a bearing
into a housing, only apply force to the outer ring of the bearing.
z In the case of grease lubricated bearings, fill the space between the bearing and outer seal with the
recommended grade of grease before installing the seal.
z Always make suitable reference marks between the components of separable bearings e.g. taper roller
bearings when disassembling to make sure correct location of components when assembling. Never install
new rollers in an outer ring, always install a new bearing assembly.
Brake Pads and Linings
Always install the correct grade and specification of brake pads and linings. When replacing these items, always
replace as complete axle sets.
CAUTION: Service tools have been developed for removing the majority of bearings; these must
always be used where specified.
CAUTION: Service tools have been developed for installing the majority of bearings; these must
always be used where specified.
CAUTION: When a waxed oil seal (installed dry) type of oil seal is to be installed, take great care that
grease does not contaminate the running surface of the seal.
When removing and installing bearings, make sure that the following practices are observed to make sure component
serviceability:
z Remove all traces from bearing under inspection by cleaning with a suitable degreasant; maintain absolute
cleanliness throughout operations.
z Conduct a visual inspection for markings on rolling elements, raceways, outer surfaces of outer or inner
surfaces of inner rings. Reject any bearings found to be marked since marking in these areas indicates onset
of wear.
z Hold inner race of bearing between finger and thumb of one hand and rotate outer race to check that it
revolves absolutely smoothly. Repeat holding outer race and rotating inner race. DO NOT spin the bearing.
z Rotate outer ring gently using a reciprocating movement whilst holding inner ring; feel for any check or
obstruction to rotation. Reject bearing if movement is not absolutely smooth.
z Check bearing for blueing or signs of overheating.
z Lubricate bearing with the specified lubricant.
z Inspect bearing surface of shaft and bearing housing for discolouration or other markings which indicate
overheating of bearing or movement between bearing and seating.
z Before installing bearing, make sure that shaft and bearing housing are clean and free from burrs.
z If one bearing of a pair shows signs of wear, overheating etc., it is advisable to replace bearings as a pair
unless it is suspected that one bearing may have been faulty when installed, was installed incorrectly or the
fault arose due to oil seal failure.
z Never reinstall a bearing unless it is in a fully serviceable condition.
z When installing a bearing to a shaft, only apply force to the inner ring of the bearing. When installing a bearing
into a housing, only apply force to the outer ring of the bearing.
z In the case of grease lubricated bearings, fill the space between the bearing and outer seal with the
recommended grade of grease before installing the seal.
z Always make suitable reference marks between the components of separable bearings e.g. taper roller
bearings when disassembling to make sure correct location of components when assembling. Never install
new rollers in an outer ring, always install a new bearing assembly.
Brake Pads and Linings
Always install the correct grade and specification of brake pads and linings. When replacing these items, always
replace as complete axle sets.
CAUTION: Service tools have been developed for removing the majority of bearings; these must
always be used where specified.
CAUTION: Service tools have been developed for installing the majority of bearings; these must
always be used where specified.
CAUTION: When a waxed oil seal (installed dry) type of oil seal is to be installed, take great care that
grease does not contaminate the running surface of the seal.
Brake Hydraulics
Always observe the following recommendations when working on the braking system:
z Always use two spanners when loosening or tightening brake pipes or hose connections.
z Make sure that hoses run in a natural curve and are not kinked or twisted.
z install brake pipes and hoses securely in their retaining clips and make sure that they cannot contact a
potential chafing point.
z Containers used for brake fluid must be kept absolutely clean.
z Do not store brake fluid in unsealed containers, the fluid will absorb water which will lower the boiling point of
the fluid.
z Do not allow brake fluid to be contaminated with other fluids such as mineral oil and do not put brake fluid in a
container which has previously been used for storing other fluids.
z Do not re-use brake fluid which has been bled from the system.
z Always use brake fluid or a suitable brake cleaning fluid to clean hydraulic components.
z Unless stated otherwise, use only clean brake fluid to lubricate hydraulic seals and components.
z Always install blanking plugs to hoses, pipes or components immediately after disconnection.
z Check thread compatibility of original equipment with replacement components.
z Observe absolute cleanliness when working with hydraulic components.
Pipes and Hoses
When removing or installing flexible hydraulic pipes and hoses, make sure that the following procedures are observed
to make sure component serviceability:
z Prior to removal, clean area around hose or pipe end which is to be disconnected.
z Obtain appropriate blanking plugs or caps before disconnecting hose or pipe end fittings in order that
connections can be plugged immediately following disconnection.
z Always install blanking plugs or caps to pipes and unions immediately following disconnection.
z Clean hose or pipe and blow through with an air line.
z Check hoses externally for cracks, separation of plies, security of end fittings and external damage; replace
faulty hoses.
z Check pipes for signs of corrosion and chafing, replace as necessary.
z When installing hoses, make sure that no unnecessary bends are introduced and that hoses are not kinked,
twisted or positioned close to potential chafing points.
z When installing pipes, make sure that pipes are positioned and clipped clear of potential chafing points.
z Always replace sealing washers installed to banjo bolts, sealing plugs etc.
z Always use a backing spanner when tightening unions and do not overtighten union nuts or banjo bolts.
z After engagement of 'quick-fit' connection hoses, perform a 'tug' test to make sure connection is securely
installed.
z After any work on hydraulic systems, always check for fluid leaks whilst a second operator applies working
pressure to the brake pedal or operates the system that has been worked on.
Fuel system hoses
Some fuel hoses are made up of two laminations, an armoured rubber outer sleeve and an inner viton core.
Whenever a hose is removed, make sure that the inner bore is inspected to check that the viton lining has not
become separated from the outer sleeve.
WARNING: Do not intermix brake fluid of different specifications.
WARNING: Suitable eye protection must be worn.
CAUTION: If pipes are found to be chafed, rectify clips, mounting points etc., to prevent further
problems in service.
Always observe the following recommendations when working on the braking system:
z Always use two spanners when loosening or tightening brake pipes or hose connections.
z Make sure that hoses run in a natural curve and are not kinked or twisted.
z install brake pipes and hoses securely in their retaining clips and make sure that they cannot contact a
potential chafing point.
z Containers used for brake fluid must be kept absolutely clean.
z Do not store brake fluid in unsealed containers, the fluid will absorb water which will lower the boiling point of
the fluid.
z Do not allow brake fluid to be contaminated with other fluids such as mineral oil and do not put brake fluid in a
container which has previously been used for storing other fluids.
z Do not re-use brake fluid which has been bled from the system.
z Always use brake fluid or a suitable brake cleaning fluid to clean hydraulic components.
z Unless stated otherwise, use only clean brake fluid to lubricate hydraulic seals and components.
z Always install blanking plugs to hoses, pipes or components immediately after disconnection.
z Check thread compatibility of original equipment with replacement components.
z Observe absolute cleanliness when working with hydraulic components.
Pipes and Hoses
When removing or installing flexible hydraulic pipes and hoses, make sure that the following procedures are observed
to make sure component serviceability:
z Prior to removal, clean area around hose or pipe end which is to be disconnected.
z Obtain appropriate blanking plugs or caps before disconnecting hose or pipe end fittings in order that
connections can be plugged immediately following disconnection.
z Always install blanking plugs or caps to pipes and unions immediately following disconnection.
z Clean hose or pipe and blow through with an air line.
z Check hoses externally for cracks, separation of plies, security of end fittings and external damage; replace
faulty hoses.
z Check pipes for signs of corrosion and chafing, replace as necessary.
z When installing hoses, make sure that no unnecessary bends are introduced and that hoses are not kinked,
twisted or positioned close to potential chafing points.
z When installing pipes, make sure that pipes are positioned and clipped clear of potential chafing points.
z Always replace sealing washers installed to banjo bolts, sealing plugs etc.
z Always use a backing spanner when tightening unions and do not overtighten union nuts or banjo bolts.
z After engagement of 'quick-fit' connection hoses, perform a 'tug' test to make sure connection is securely
installed.
z After any work on hydraulic systems, always check for fluid leaks whilst a second operator applies working
pressure to the brake pedal or operates the system that has been worked on.
Fuel system hoses
Some fuel hoses are made up of two laminations, an armoured rubber outer sleeve and an inner viton core.
Whenever a hose is removed, make sure that the inner bore is inspected to check that the viton lining has not
become separated from the outer sleeve.
WARNING: Do not intermix brake fluid of different specifications.
WARNING: Suitable eye protection must be worn.
CAUTION: If pipes are found to be chafed, rectify clips, mounting points etc., to prevent further
problems in service.
Fuel system hose clips
Certain fuel system hose clips are of the 'break-off head' type where a slot in the screw head shears off when the clip
is tightened to a specific torque. These clips may be removed using a screwdriver and must be replaced with new
clips on reassembly. Clips must be tightened until the portion of the slot shears off. Do not attempt to tighten clips by
any other method, do not install any other type of clip.
'Quick-fit' connections are also installed to certain fuel hoses. After engagement of 'quick-fit' connections, perform a
'tug' test to make sure connection is securely installed.
Other fuel system hose clips are of the 'Jubilee' type and there may be a tamper proof cover installed over the screw
head. These cover must be carefully removed before slackening the clip and should be replaced after final tightening,
ensuring that the internal hexagon on the cover is correctly located on the clip screw.
Cooling system hoses
Hose orientation and connection
Correct orientation of cooling system hoses is important to make sure that hoses do not become fatigued or damaged
through contact with adjacent components.
Where orientation marks are provided on the hose and corresponding component, the marks must be aligned when
the hose is installed. Hoses must be installed fully on to their connection points, usually a moulded form on a pipe
provides a positive indicator.
WARNING: Never attempt to repair fuel hoses or rectify leaking 'quick-fit' connectors. The fuel hose
and connectors must be replaced as an assembly.
CAUTION: The following precautions must be observed to make sure that the integrity of the cooling
system hoses and their connection to the system is maintained.
Certain fuel system hose clips are of the 'break-off head' type where a slot in the screw head shears off when the clip
is tightened to a specific torque. These clips may be removed using a screwdriver and must be replaced with new
clips on reassembly. Clips must be tightened until the portion of the slot shears off. Do not attempt to tighten clips by
any other method, do not install any other type of clip.
'Quick-fit' connections are also installed to certain fuel hoses. After engagement of 'quick-fit' connections, perform a
'tug' test to make sure connection is securely installed.
Other fuel system hose clips are of the 'Jubilee' type and there may be a tamper proof cover installed over the screw
head. These cover must be carefully removed before slackening the clip and should be replaced after final tightening,
ensuring that the internal hexagon on the cover is correctly located on the clip screw.
Cooling system hoses
Hose orientation and connection
Correct orientation of cooling system hoses is important to make sure that hoses do not become fatigued or damaged
through contact with adjacent components.
Where orientation marks are provided on the hose and corresponding component, the marks must be aligned when
the hose is installed. Hoses must be installed fully on to their connection points, usually a moulded form on a pipe
provides a positive indicator.
WARNING: Never attempt to repair fuel hoses or rectify leaking 'quick-fit' connectors. The fuel hose
and connectors must be replaced as an assembly.
CAUTION: The following precautions must be observed to make sure that the integrity of the cooling
system hoses and their connection to the system is maintained.
Hose clips
Markings are usually provided on the hose to indicate the correct clip position. If no markings are provided, position
the clip directly behind the retaining lip at the end of the stub pipe. Worm drive clips should be orientated with the
crimped side of the drive housing facing towards the end of the hose or the hose may become pinched between the
clip and the stub pipe retaining lip. Unless otherwise stated, worm drive clips should be tightened to 3 Nm (2 lb-ft).
Make sure that hose clips do not foul adjacent components.
Oetiker clips may be removed by bending the tag (arrowed) and releasing the free end of the clip. Clips must not be
re-used. When installing new clips, make sure clip is positioned on hose before tightening and make sure that when
clip is tightened, the tag is located in the longitudinal slot in the free end of the clip (arrowed in illustration).
'Quick-fit' connections are also installed to certain hoses/pipes. Inspect 'quick-fit' connections for damage, prior to
connection. Replace if damaged. After engagement of 'quick-fit' connections, perform a 'tug' test to make sure
connection is securely installed.
Heat protection
Always make sure that heat shields and protective sheathing are in good condition; replace if damage is evident.
Particular care must be taken when routing hoses close to hot engine components such as the exhaust manifolds
and exhaust gas recirculation (EGR) pipes. Hoses will relax and deflect slightly when hot, make sure this movement
is taken into account when routing and securing hoses.
Electrical Precautions
General
The following guidelines are intended to make sure the safety of the operator whilst preventing damage to the
electrical and electronic components of this vehicle.
Equipment
Prior to commencing any test procedure on the vehicle, make sure that the relevant test equipment is working
correctly and that any harness or connectors are in good condition. It is particularly important to check the condition
of all plugs and leads of mains operated equipment.
Polarity
Markings are usually provided on the hose to indicate the correct clip position. If no markings are provided, position
the clip directly behind the retaining lip at the end of the stub pipe. Worm drive clips should be orientated with the
crimped side of the drive housing facing towards the end of the hose or the hose may become pinched between the
clip and the stub pipe retaining lip. Unless otherwise stated, worm drive clips should be tightened to 3 Nm (2 lb-ft).
Make sure that hose clips do not foul adjacent components.
Oetiker clips may be removed by bending the tag (arrowed) and releasing the free end of the clip. Clips must not be
re-used. When installing new clips, make sure clip is positioned on hose before tightening and make sure that when
clip is tightened, the tag is located in the longitudinal slot in the free end of the clip (arrowed in illustration).
'Quick-fit' connections are also installed to certain hoses/pipes. Inspect 'quick-fit' connections for damage, prior to
connection. Replace if damaged. After engagement of 'quick-fit' connections, perform a 'tug' test to make sure
connection is securely installed.
Heat protection
Always make sure that heat shields and protective sheathing are in good condition; replace if damage is evident.
Particular care must be taken when routing hoses close to hot engine components such as the exhaust manifolds
and exhaust gas recirculation (EGR) pipes. Hoses will relax and deflect slightly when hot, make sure this movement
is taken into account when routing and securing hoses.
Electrical Precautions
General
The following guidelines are intended to make sure the safety of the operator whilst preventing damage to the
electrical and electronic components of this vehicle.
Equipment
Prior to commencing any test procedure on the vehicle, make sure that the relevant test equipment is working
correctly and that any harness or connectors are in good condition. It is particularly important to check the condition
of all plugs and leads of mains operated equipment.
Polarity
Never reverse connect the vehicle battery and always make sure the correct polarity when connecting test
equipment.
High voltage circuits
Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead to
contact other components, particularly ECU's.
Connectors and harnesses
The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors.
Always observe the following:
z Make sure electrically related items are dry and oil free before disconnecting/connecting test equipment.
z Make sure that disconnected multiplugs and sensors are protected from any possible oil, coolant or other
liquid contamination. Any such contamination could impair performance or lead to component failure.
z Never force connectors apart or pull on the wiring harness.
z Always make sure locking tabs are disengaged before disconnecting multiplugs etc. and make sure that
correct orientation is achieved before connection.
z Make sure that any protection covers, insulation etc. are replaced if disturbed.
Having confirmed that a component is faulty, carry out th following:
z Switch off the ignition and disconnect the battery.
z Remove the component and support the disconnected harness.
z When replacing electrical components, keep oily hands away from electrical connections and make sure that
locking tabs on connectors are fully engaged.
Battery Disconnection/Connection
Always refer to the Electrical Section of this manual - Battery Connection/Disconnection prior to attempting to connect
or disconnect the battery. For additional information, refer to Battery (414-01 Battery, Mounting and Cables)
Fuel Handling Precautions
The following information lists basic precautions which must be observed if fuel is to be handled safely. It also
outlines other areas of risk which must not be ignored. As this information is issued for basic guidance only, consult
your local Fire Department where any doubt as to personal and environmental safety exists - See also Health and
Safety Precautions.
General precautions
Always have the correct type of fire extinguisher containing Foam, CO2, Gas or powder accessible when handling or
draining fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.
Make sure that suitable warning signs are exhibited.
Keep all sources of ignition well away from areas where fuel is being handled.
Make sure that any leadlamps are flameproof and kept clear of spillage.
Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel system.
WARNING: Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.
WARNING: No one should be permitted to repair components associated with fuel without first
having specialist training.
equipment.
High voltage circuits
Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead to
contact other components, particularly ECU's.
Connectors and harnesses
The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors.
Always observe the following:
z Make sure electrically related items are dry and oil free before disconnecting/connecting test equipment.
z Make sure that disconnected multiplugs and sensors are protected from any possible oil, coolant or other
liquid contamination. Any such contamination could impair performance or lead to component failure.
z Never force connectors apart or pull on the wiring harness.
z Always make sure locking tabs are disengaged before disconnecting multiplugs etc. and make sure that
correct orientation is achieved before connection.
z Make sure that any protection covers, insulation etc. are replaced if disturbed.
Having confirmed that a component is faulty, carry out th following:
z Switch off the ignition and disconnect the battery.
z Remove the component and support the disconnected harness.
z When replacing electrical components, keep oily hands away from electrical connections and make sure that
locking tabs on connectors are fully engaged.
Battery Disconnection/Connection
Always refer to the Electrical Section of this manual - Battery Connection/Disconnection prior to attempting to connect
or disconnect the battery. For additional information, refer to Battery (414-01 Battery, Mounting and Cables)
Fuel Handling Precautions
The following information lists basic precautions which must be observed if fuel is to be handled safely. It also
outlines other areas of risk which must not be ignored. As this information is issued for basic guidance only, consult
your local Fire Department where any doubt as to personal and environmental safety exists - See also Health and
Safety Precautions.
General precautions
Always have the correct type of fire extinguisher containing Foam, CO2, Gas or powder accessible when handling or
draining fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.
Make sure that suitable warning signs are exhibited.
Keep all sources of ignition well away from areas where fuel is being handled.
Make sure that any leadlamps are flameproof and kept clear of spillage.
Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel system.
WARNING: Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.
WARNING: No one should be permitted to repair components associated with fuel without first
having specialist training.
Fuel tank and system draining
Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of this
manual.
Always release pipe clips fully before attempting to disconnect fuel pipes.
Fuel tank repairs
Oil seals
Never use a seal which has been improperly stored or handled.
z Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
z Carefully examine seal before installing to make sure that it is clean and undamaged.
z Make sure that the surface on which the seal is to run and also the seal housing is clean and free from burrs
or scratches. Renew the component if the sealing surface cannot be restored.
z Special tools and protection sleeves are provided for installing the majority of seals and must be used when
specified.
z Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to installing.
Always check the relevant repair procedure which will state if a seal must be installed dry. Never touch these
seals with oily hands as the oil will contaminate the protective coating and affect the sealing properties of the
seal; also, make sure that installing tools and protection sleeves are free from oil and grease. Seals which
must be lubricated prior to installing should have the recommended lubricant applied to the areas specified in
the repair procedure.
z Make sure that a seal is installed the correct way round. For example, the lip of the seal must face towards
the lubricant which it is sealing.
z When installing an oil seal, make sure that it is positioned square to shaft and housing. Where the seal is to
be installed to a housing prior to installing over a shaft, take care not to allow the weight of an unsupported
shaft to rest on the seal.
WARNING: Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or
draining of fuel must be carried out in a well ventilated area.
WARNING: Never switch on or operate mobile (cellular) phones in the vicinity of vehicles when
operations are being carried out on the fuel system.
WARNING: Always attach fuel vapour warning labels to fuel tanks immediately after draining.
WARNING: Containers used for storing fuel must be clearly marked with the contents and placed in
a safe storage area which meets the requirements of the local authority.
CAUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is
damaged, no attempt must be made to repair the connector, a new fuel line and connector(s) assembly
must be installed.
CAUTION: No attempt should be made to repair a fuel tank. If the structure of the tank is damaged, a
new tank must be installed.
Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of this
manual.
Always release pipe clips fully before attempting to disconnect fuel pipes.
Fuel tank repairs
Oil seals
Never use a seal which has been improperly stored or handled.
z Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
z Carefully examine seal before installing to make sure that it is clean and undamaged.
z Make sure that the surface on which the seal is to run and also the seal housing is clean and free from burrs
or scratches. Renew the component if the sealing surface cannot be restored.
z Special tools and protection sleeves are provided for installing the majority of seals and must be used when
specified.
z Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to installing.
Always check the relevant repair procedure which will state if a seal must be installed dry. Never touch these
seals with oily hands as the oil will contaminate the protective coating and affect the sealing properties of the
seal; also, make sure that installing tools and protection sleeves are free from oil and grease. Seals which
must be lubricated prior to installing should have the recommended lubricant applied to the areas specified in
the repair procedure.
z Make sure that a seal is installed the correct way round. For example, the lip of the seal must face towards
the lubricant which it is sealing.
z When installing an oil seal, make sure that it is positioned square to shaft and housing. Where the seal is to
be installed to a housing prior to installing over a shaft, take care not to allow the weight of an unsupported
shaft to rest on the seal.
WARNING: Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or
draining of fuel must be carried out in a well ventilated area.
WARNING: Never switch on or operate mobile (cellular) phones in the vicinity of vehicles when
operations are being carried out on the fuel system.
WARNING: Always attach fuel vapour warning labels to fuel tanks immediately after draining.
WARNING: Containers used for storing fuel must be clearly marked with the contents and placed in
a safe storage area which meets the requirements of the local authority.
CAUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is
damaged, no attempt must be made to repair the connector, a new fuel line and connector(s) assembly
must be installed.
CAUTION: No attempt should be made to repair a fuel tank. If the structure of the tank is damaged, a
new tank must be installed.
z Always use the recommended special tool and protection sleeve to install an oil seal. If no tool is specified,
use a suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter of the seal. Use
adhesive tape on the shaft to protect the sealing lip of the seal.
z Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face of the
housing where no shoulder is provided. Make sure that the seal is not tilted in the housing when it is installed.
(A/C) System Precautions
The A/C system contains fluids and components which could be potentially hazardous to the service engineer or the
environment if not serviced and handled correctly. The following guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the importance of ensuring the integrity of the A/C operating conditions
and components installed to the vehicle.
Where necessary, additional specific precautions are detailed in the relevant sections of this Manual and also in the
Health and Safety Section. These precautions must be referred to prior to commencing repair operations.
The refrigerant used in the A/C system is HC-134a (Hydro fluorocarbon) R134a.
Remedial actions
If an accident involving R134a should occur, conduct the following remedial actions:
WARNING: Servicing must only be carried out by personnel familiar with both the vehicle system
and the charging and testing equipment. All operations must be carried out in a well ventilated area away
from open flame and heat sources.
WARNING: R134a is a hazardous liquid and when handled incorrectly can cause serious injury.
Suitable protective clothing, consisting of face protection, heat proof gloves, rubber boots and rubber
apron or waterproof overalls, must be worn when carrying out operations on the A/C system.
WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a
splashed on any part of the body will cause immediate freezing of that area. Also, refrigerant cylinders and
replenishment trolleys when discharging will freeze skin to them if contact is made.
use a suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter of the seal. Use
adhesive tape on the shaft to protect the sealing lip of the seal.
z Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face of the
housing where no shoulder is provided. Make sure that the seal is not tilted in the housing when it is installed.
(A/C) System Precautions
The A/C system contains fluids and components which could be potentially hazardous to the service engineer or the
environment if not serviced and handled correctly. The following guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the importance of ensuring the integrity of the A/C operating conditions
and components installed to the vehicle.
Where necessary, additional specific precautions are detailed in the relevant sections of this Manual and also in the
Health and Safety Section. These precautions must be referred to prior to commencing repair operations.
The refrigerant used in the A/C system is HC-134a (Hydro fluorocarbon) R134a.
Remedial actions
If an accident involving R134a should occur, conduct the following remedial actions:
WARNING: Servicing must only be carried out by personnel familiar with both the vehicle system
and the charging and testing equipment. All operations must be carried out in a well ventilated area away
from open flame and heat sources.
WARNING: R134a is a hazardous liquid and when handled incorrectly can cause serious injury.
Suitable protective clothing, consisting of face protection, heat proof gloves, rubber boots and rubber
apron or waterproof overalls, must be worn when carrying out operations on the A/C system.
WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a
splashed on any part of the body will cause immediate freezing of that area. Also, refrigerant cylinders and
replenishment trolleys when discharging will freeze skin to them if contact is made.
z If liquid R134a enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye to raise
the temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing,
cover the eye with a clean pad and seek immediate medical attention.
z If liquid R134a is splashed onto the skin, run large quantities of water over the affected area to raise the
temperature. Implement the same action if the skin comes in contact with discharging cylinders. Wrap the
contaminated body parts in blankets (or similar materials) and seek immediate medical attention.
z If the debilitating effects of inhalation of R134a vapour are suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated area to fresh air and apply artificial respiration and/or
oxygen and seek immediate medical attention.
Service precautions
Observe the following precautions when handling components used in the system:
z A/C units must not be lifted by their hoses, pipes or capillary lines.
z Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by
kinks or restrictions. Make sure that hoses are correctly positioned before tightening couplings, and make
sure that all clips and supports are utilised.
z Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected
by heat shielding.
z Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of
components and panels may transmit noise and so must be eliminated.
z The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value.
An additional spanner must be used to hold the union to prevent twisting of the pipe when tightening
connections.
z Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-rings,
BUT NOT to the threads of the connection.
z All protective plugs or caps must remain in place in the component until immediately prior to connection.
z Make sure components are at room temperature before uncapping/unplugging, to prevent condensation of
moisture from the air that enters it.
z When disconnecting, immediately plug or cap all pipes to prevent ingress of dirt and moisture into the system.
z Components must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for 24
hours or longer, a new receiver/drier must be installed.
z The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A
receiver/drier that has been left uncapped for longer than 24 hours must not be used; install a new unit.
z The receiver/drier should be the last component connected to the system to make sure optimum dehydration
and maximum moisture protection of the system.
z Whenever a component of the refrigeration system is replaced, it will also be necessary to install a new
receiver/drier unit.
z Use alcohol and a clean lint-free cloth to clean dirty connections.
z Make sure that all new parts installed are marked for use with R134a.
z When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of this
manual for the correct procedure.
Refrigerant oil
When replacing components in the system, drain the refrigerant oil from the component being replaced into a
graduated container. On assembly, add the quantity of refrigerant oil drained to the new component - See
Compressor Replacement in this Section.
A/C Compressor
A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly release
the sealing cap; gas pressure should be heard to vent as the seal is broken.
CAUTION: Refrigerant oil (ND-8 PAG) easily absorbs water and must not be stored for long periods.
Do not pour unused refrigerant oil back into the container. Always use an approved refrigerant oil.
the temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing,
cover the eye with a clean pad and seek immediate medical attention.
z If liquid R134a is splashed onto the skin, run large quantities of water over the affected area to raise the
temperature. Implement the same action if the skin comes in contact with discharging cylinders. Wrap the
contaminated body parts in blankets (or similar materials) and seek immediate medical attention.
z If the debilitating effects of inhalation of R134a vapour are suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated area to fresh air and apply artificial respiration and/or
oxygen and seek immediate medical attention.
Service precautions
Observe the following precautions when handling components used in the system:
z A/C units must not be lifted by their hoses, pipes or capillary lines.
z Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by
kinks or restrictions. Make sure that hoses are correctly positioned before tightening couplings, and make
sure that all clips and supports are utilised.
z Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected
by heat shielding.
z Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of
components and panels may transmit noise and so must be eliminated.
z The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value.
An additional spanner must be used to hold the union to prevent twisting of the pipe when tightening
connections.
z Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-rings,
BUT NOT to the threads of the connection.
z All protective plugs or caps must remain in place in the component until immediately prior to connection.
z Make sure components are at room temperature before uncapping/unplugging, to prevent condensation of
moisture from the air that enters it.
z When disconnecting, immediately plug or cap all pipes to prevent ingress of dirt and moisture into the system.
z Components must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for 24
hours or longer, a new receiver/drier must be installed.
z The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A
receiver/drier that has been left uncapped for longer than 24 hours must not be used; install a new unit.
z The receiver/drier should be the last component connected to the system to make sure optimum dehydration
and maximum moisture protection of the system.
z Whenever a component of the refrigeration system is replaced, it will also be necessary to install a new
receiver/drier unit.
z Use alcohol and a clean lint-free cloth to clean dirty connections.
z Make sure that all new parts installed are marked for use with R134a.
z When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of this
manual for the correct procedure.
Refrigerant oil
When replacing components in the system, drain the refrigerant oil from the component being replaced into a
graduated container. On assembly, add the quantity of refrigerant oil drained to the new component - See
Compressor Replacement in this Section.
A/C Compressor
A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly release
the sealing cap; gas pressure should be heard to vent as the seal is broken.
CAUTION: Refrigerant oil (ND-8 PAG) easily absorbs water and must not be stored for long periods.
Do not pour unused refrigerant oil back into the container. Always use an approved refrigerant oil.
Rapid refrigerant discharge
If the A/C system is damaged as a result of an accident and the system is punctured, the refrigerant will discharge
rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The
compressor must be removed and all the remaining oil in the compressor drained and refilled as instructed in the air
conditioning section of this manual.
Precautions for refrigerant recovery, recycling and recharging
When the A/C system is recharged, any existing refrigerant is first recovered from the system and recycled. The
system is then charged with the required weight of refrigerant and volume of refrigerant oil.
A/C Compressor Replacement
A new compressor is supplied filled with a full charge (X cm³) of refrigerant oil.
A calculated quantity of oil must be drained from the new compressor before installing. To calculate the quantity of oil
to be drained:
z Remove the drain plug from the old compressor.
z Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor
clutch to make sure the compressor is completely drained.
z Note the quantity of oil drained (Y cm³).
z Calculate the quantity of oil to be drained from the new compressor using the following formula:X cm³ — (Y
cm³ + 20 cm³) = Q cm³
z Remove the drain plug from the new compressor and drain Q cm³ of oil. Install and tighten the compressor
drain plug.
Vehicle Weights up to 07/2001
When loading a vehicle to its maximum (Gross Vehicle Weight) consideration must be taken of the unladen vehicle
weight and distribution of the payload to make sure that axle loadings do not exceed the permitted maximum values.
It is the customer's repsonsibility to limit the vehicle's payload in an appropriate manner such that neither maximum
axle loads nor Gross Vehicle Weight are exceeded.
NOTE:
CAUTION: A new compressor should always be sealed and could be pressurised with nitrogen gas.
To avoid possible oil loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately
prior to connecting the pipes to the compressor.
WARNING: Refrigerant must always be recycled before re-use to make sure that the purity of the
refrigerant is high enough for safe use in the system. Recycling should always be carried out with
equipment which is design certified by Underwriter Laboratory Inc. for compliance with SAE J1991. Other
equipment may not recycle refrigerant to the required level of purity.
CAUTION: A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any
other type of refrigerant. Refrigerant R134a from domestic and commercial sources must not be used in
motor vehicle systems.
CAUTION: The system must be evacuated immediately before recharging commences. Delay
between evacuation and recharging is not permitted.
If the A/C system is damaged as a result of an accident and the system is punctured, the refrigerant will discharge
rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The
compressor must be removed and all the remaining oil in the compressor drained and refilled as instructed in the air
conditioning section of this manual.
Precautions for refrigerant recovery, recycling and recharging
When the A/C system is recharged, any existing refrigerant is first recovered from the system and recycled. The
system is then charged with the required weight of refrigerant and volume of refrigerant oil.
A/C Compressor Replacement
A new compressor is supplied filled with a full charge (X cm³) of refrigerant oil.
A calculated quantity of oil must be drained from the new compressor before installing. To calculate the quantity of oil
to be drained:
z Remove the drain plug from the old compressor.
z Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor
clutch to make sure the compressor is completely drained.
z Note the quantity of oil drained (Y cm³).
z Calculate the quantity of oil to be drained from the new compressor using the following formula:X cm³ — (Y
cm³ + 20 cm³) = Q cm³
z Remove the drain plug from the new compressor and drain Q cm³ of oil. Install and tighten the compressor
drain plug.
Vehicle Weights up to 07/2001
When loading a vehicle to its maximum (Gross Vehicle Weight) consideration must be taken of the unladen vehicle
weight and distribution of the payload to make sure that axle loadings do not exceed the permitted maximum values.
It is the customer's repsonsibility to limit the vehicle's payload in an appropriate manner such that neither maximum
axle loads nor Gross Vehicle Weight are exceeded.
NOTE:
CAUTION: A new compressor should always be sealed and could be pressurised with nitrogen gas.
To avoid possible oil loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately
prior to connecting the pipes to the compressor.
WARNING: Refrigerant must always be recycled before re-use to make sure that the purity of the
refrigerant is high enough for safe use in the system. Recycling should always be carried out with
equipment which is design certified by Underwriter Laboratory Inc. for compliance with SAE J1991. Other
equipment may not recycle refrigerant to the required level of purity.
CAUTION: A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any
other type of refrigerant. Refrigerant R134a from domestic and commercial sources must not be used in
motor vehicle systems.
CAUTION: The system must be evacuated immediately before recharging commences. Delay
between evacuation and recharging is not permitted.
NOTE:
90 Models
110 Models
130 Models
Vehicle Weights From 07/2001
90 Models
Axle weights are not accumulative. The individual maximum axle weights and gross vehicle weights must not
be exceeded.
EEC Kerb weight = Unladen weight + full fuel tank + 75 Kg (165lb).
Vehicle axle weights - Standard Standard High load High load
Front axle 1200 Kg 2645 lb 1200 Kg 2645 lb
Rear axle 1380 Kg 3042 lb 1500 Kg 3307 lb
Maximum Gross Vehicle Weight (GVW) - 2400 Kg 5291 lb 2550 5622 lb
EEC Vehicle kerb weights
Soft top 1695 Kg 3736 lb 1699 Kg 3745 lb
Pick-up 1694 Kg 3734 lb 1698 Kg 3743 lb
Hard top 1746 Kg 3849 lb 1750 Kg 3858 lb
Station wagon 1793 Kg 3952 lb 1797 Kg 3961 lb
Vehicle axle weights - Levelled Levelled Unlevelled Unlevelled
Front axle 1200 Kg 2645 lb 1200 Kg 2645 lb
Rear axle 1750 Kg 3858 lb 1850 Kg 4078 lb
Maximum Gross Vehicle Weight (GVW) - 2950 Kg 6503 lb 3050 Kg 6724 lb
EEC Vehicle kerb weights Standard Standard High load High load
Soft top 1872 Kg 4127 lb 1882 KG 4149 lb
Pick-up 1880 Kg 4144 lb 1890 Kg 4166 lb
High capacity Pick-up 1917 Kg 4226 lb 1927 Kg 4248 lb
Hard top 1913 Kg 4217 lb 1923 Kg 4239 lb
Station wagon 2018 Kg 4448 lb 2018 Kg 4470 lb
County station wagon 2054 Kg 4528 lb 2054 Kg 455 lb
Vehicle axle weights - 130 models
Front axle 1580 kg 3483 lb
Rear axle 2200 Kg 4850 lb
Maximum Gross Vehicle Weight (GVW) - 3500 kg 7716 lb
EEC Vehicle kerb weights
Crew cab and high capacity pick-up 2086 Kg 4598 lb
Vehicle axle weights - 90 models Station wagon Station wagon Utility Utility
Front axle 1200 Kg 2645 lb 1200 Kg 2645 lb
Rear axle 1500 Kg 3307 lb 1500 Kg 3307 lb
Maximum Gross Vehicle Weight (GVW) - 2550 Kg 5622 lb 2400 5291 lb
EEC Vehicle kerb weights
Soft top 1770 Kg 3402 lb 1993 Kg 4393 lb
90 Models
110 Models
130 Models
Vehicle Weights From 07/2001
90 Models
Axle weights are not accumulative. The individual maximum axle weights and gross vehicle weights must not
be exceeded.
EEC Kerb weight = Unladen weight + full fuel tank + 75 Kg (165lb).
Vehicle axle weights - Standard Standard High load High load
Front axle 1200 Kg 2645 lb 1200 Kg 2645 lb
Rear axle 1380 Kg 3042 lb 1500 Kg 3307 lb
Maximum Gross Vehicle Weight (GVW) - 2400 Kg 5291 lb 2550 5622 lb
EEC Vehicle kerb weights
Soft top 1695 Kg 3736 lb 1699 Kg 3745 lb
Pick-up 1694 Kg 3734 lb 1698 Kg 3743 lb
Hard top 1746 Kg 3849 lb 1750 Kg 3858 lb
Station wagon 1793 Kg 3952 lb 1797 Kg 3961 lb
Vehicle axle weights - Levelled Levelled Unlevelled Unlevelled
Front axle 1200 Kg 2645 lb 1200 Kg 2645 lb
Rear axle 1750 Kg 3858 lb 1850 Kg 4078 lb
Maximum Gross Vehicle Weight (GVW) - 2950 Kg 6503 lb 3050 Kg 6724 lb
EEC Vehicle kerb weights Standard Standard High load High load
Soft top 1872 Kg 4127 lb 1882 KG 4149 lb
Pick-up 1880 Kg 4144 lb 1890 Kg 4166 lb
High capacity Pick-up 1917 Kg 4226 lb 1927 Kg 4248 lb
Hard top 1913 Kg 4217 lb 1923 Kg 4239 lb
Station wagon 2018 Kg 4448 lb 2018 Kg 4470 lb
County station wagon 2054 Kg 4528 lb 2054 Kg 455 lb
Vehicle axle weights - 130 models
Front axle 1580 kg 3483 lb
Rear axle 2200 Kg 4850 lb
Maximum Gross Vehicle Weight (GVW) - 3500 kg 7716 lb
EEC Vehicle kerb weights
Crew cab and high capacity pick-up 2086 Kg 4598 lb
Vehicle axle weights - 90 models Station wagon Station wagon Utility Utility
Front axle 1200 Kg 2645 lb 1200 Kg 2645 lb
Rear axle 1500 Kg 3307 lb 1500 Kg 3307 lb
Maximum Gross Vehicle Weight (GVW) - 2550 Kg 5622 lb 2400 5291 lb
EEC Vehicle kerb weights
Soft top 1770 Kg 3402 lb 1993 Kg 4393 lb
110 Models - Non Japanese specification
110 Models - Japanese specification
130 Models
Towing weights
NOTE:
NOTE:
Off Road Performance
90 Models
NOTE:
Pick -up 1770 Kg 3402 lb 1993 Kg 4393 lb
Hard top 1815 Kg 4001 lb 1987 Kg 4380 lb
Station wagon 1870- 1885 Kg 4122 - 4155 lb 1989 - 1998 Kg 4385 - 4404 lb
Vehicle axle weights - Station wagon Station wagon Utility Utility
Front axle 1200 Kg 2645 lb 1200 Kg 2645 lb
Rear axle 1750 Kg 3858 lb 1850 Kg 4078 lb
Maximum Gross Vehicle Weight (GVW) - 2950 Kg 6503 lb 3050 Kg 6724 lb
EEC Vehicle kerb weights Standard Standard Heavy duty Heavy duty
Soft top 1885 Kg 4155 lb 2080 KG 4585 lb
High capacity Pick-up 1920 Kg 4232 lb 2122 Kg 4678 lb
Hard top 1920 Kg 4232 lb 2110 Kg 4651 lb
Station wagon 2055 Kg 4530 lb 2229 Kg 4914 lb
Vehicle axle weights - Metric Imperial
Front axle 1115 Kg 2457 lb
Rear axle 2180 Kg 4805 lb
Maximum Gross Vehicle Weight (GVW) - 3295 Kg 7262 lb
Vehicle axle weights Metric Imperial
Front axle 1580 kg 3483 lb
Rear axle 2200 Kg 4850 lb
Maximum Gross Vehicle Weight (GVW) - 3500 kg 7716 lb
EEC Vehicle kerb weights Heavy duty Heavy duty
Crew cab and high capacity pick-up 2177 - 2286 Kg 4667 - 5039 lb
* Only applies to vehicles modified to accept coupled brakes.
All weight figures are subject to local restrictions
Towing weights On-road On-road Off-road Off-road
Unbraked trailers 750 Kg 1653 lb 500 Kg 1102 lb
Trailers with overrun brakes 3500 Kg 7716 lb 1000 Kg 2204lb
4 wheel Trailers with coupled brakes * 4000 Kg 8818 lb 1000 Kg 2204lb
Departure angles do not account for the addition of a tow hitch.
110 Models - Japanese specification
130 Models
Towing weights
NOTE:
NOTE:
Off Road Performance
90 Models
NOTE:
Pick -up 1770 Kg 3402 lb 1993 Kg 4393 lb
Hard top 1815 Kg 4001 lb 1987 Kg 4380 lb
Station wagon 1870- 1885 Kg 4122 - 4155 lb 1989 - 1998 Kg 4385 - 4404 lb
Vehicle axle weights - Station wagon Station wagon Utility Utility
Front axle 1200 Kg 2645 lb 1200 Kg 2645 lb
Rear axle 1750 Kg 3858 lb 1850 Kg 4078 lb
Maximum Gross Vehicle Weight (GVW) - 2950 Kg 6503 lb 3050 Kg 6724 lb
EEC Vehicle kerb weights Standard Standard Heavy duty Heavy duty
Soft top 1885 Kg 4155 lb 2080 KG 4585 lb
High capacity Pick-up 1920 Kg 4232 lb 2122 Kg 4678 lb
Hard top 1920 Kg 4232 lb 2110 Kg 4651 lb
Station wagon 2055 Kg 4530 lb 2229 Kg 4914 lb
Vehicle axle weights - Metric Imperial
Front axle 1115 Kg 2457 lb
Rear axle 2180 Kg 4805 lb
Maximum Gross Vehicle Weight (GVW) - 3295 Kg 7262 lb
Vehicle axle weights Metric Imperial
Front axle 1580 kg 3483 lb
Rear axle 2200 Kg 4850 lb
Maximum Gross Vehicle Weight (GVW) - 3500 kg 7716 lb
EEC Vehicle kerb weights Heavy duty Heavy duty
Crew cab and high capacity pick-up 2177 - 2286 Kg 4667 - 5039 lb
* Only applies to vehicles modified to accept coupled brakes.
All weight figures are subject to local restrictions
Towing weights On-road On-road Off-road Off-road
Unbraked trailers 750 Kg 1653 lb 500 Kg 1102 lb
Trailers with overrun brakes 3500 Kg 7716 lb 1000 Kg 2204lb
4 wheel Trailers with coupled brakes * 4000 Kg 8818 lb 1000 Kg 2204lb
Departure angles do not account for the addition of a tow hitch.
110 and 130 Models
NOTE:
Vehicle dimensions
90 Models
110 Models
Item Metric Imperial
Max. gradient (EEC Kerb weight) 45°
Approach angle
Soft Top and Pick-up (EEC Kerb weight) 48°
Hard top and Station wagon (EEC Kerb weight) 51.5°
Departure angle
Soft Top and Pick-up (EEC Kerb weight) 49°
Hard top and Station wagon (EEC Kerb weight) 53°
Wading depth 500 mm 20 in
Min. ground clearance (unladen)
Soft Top and Pick-up (EEC Kerb weight) 191 mm 7.5 in
Hard top and Station wagon (EEC Kerb weight) 229 mm 9.0 in
Departure angles do not account for the addition of a tow hitch.
Item Metric Imperial
Max. gradient (EEC Kerb weight) 45°
Approach angle 50°
Departure angle
110 Models 35°
130 Models 34°
Wading depth 500 mm 20 in
Min. ground clearance (unladen) 215 mm 8.5 in
Item Metric Imperial
Overall length
Soft top and Pick-up 3722 mm 146.5 in
Hard top and Station wagon 3883 mm 152.9 in
Overall width 1790 mm 70.5
Overall height
Soft top and Pick-up 1965 mm 77.4 in
Pick-up and Station wagon 1963 mm 77.3 in
Hardtop 1972 mm 77.6 in
Wheelbase 2360 mm 92.9 in
Track front/rear 1486 mm 58.5 in
Width between wheel boxes 925 mm 36.4 in
Item Metric Imperial
Overall length
Soft top and Pick-up 4438 mm 175 in
Hard capacity pick-up 4631 mm 182 in
NOTE:
Vehicle dimensions
90 Models
110 Models
Item Metric Imperial
Max. gradient (EEC Kerb weight) 45°
Approach angle
Soft Top and Pick-up (EEC Kerb weight) 48°
Hard top and Station wagon (EEC Kerb weight) 51.5°
Departure angle
Soft Top and Pick-up (EEC Kerb weight) 49°
Hard top and Station wagon (EEC Kerb weight) 53°
Wading depth 500 mm 20 in
Min. ground clearance (unladen)
Soft Top and Pick-up (EEC Kerb weight) 191 mm 7.5 in
Hard top and Station wagon (EEC Kerb weight) 229 mm 9.0 in
Departure angles do not account for the addition of a tow hitch.
Item Metric Imperial
Max. gradient (EEC Kerb weight) 45°
Approach angle 50°
Departure angle
110 Models 35°
130 Models 34°
Wading depth 500 mm 20 in
Min. ground clearance (unladen) 215 mm 8.5 in
Item Metric Imperial
Overall length
Soft top and Pick-up 3722 mm 146.5 in
Hard top and Station wagon 3883 mm 152.9 in
Overall width 1790 mm 70.5
Overall height
Soft top and Pick-up 1965 mm 77.4 in
Pick-up and Station wagon 1963 mm 77.3 in
Hardtop 1972 mm 77.6 in
Wheelbase 2360 mm 92.9 in
Track front/rear 1486 mm 58.5 in
Width between wheel boxes 925 mm 36.4 in
Item Metric Imperial
Overall length
Soft top and Pick-up 4438 mm 175 in
Hard capacity pick-up 4631 mm 182 in
130 Models
V8 Models
Hardtop/station and county 4599 mm 181 in
Overall width 1790 mm 70.5 in
Overall height -
Non Japanese specification 2035 mm 80.1 in
Japanese specification 2060 mm 81.1 in
Wheelbase 2794 mm 110 in
Track front/rear 1486 mm 58.5 in
Width between wheel boxes
High capacity pick-up 1090 mm 43 in
All other models 925 mm 36.4 in
Item Metric Imperial
Overall length 5132 mm 202 in
Overall width 1790 mm 70.5 in
Overall height 2035 mm 80.1 in
Wheelbase 3266 mm 127 in
Track front/rear 1486 mm 58.5 in
Width between wheel boxes 1090 mm 43 in
Item Metric Imperial
Overall length 4072 mm 160.5 in
Overall width 1790 mm 70.5 in
Overall height 2037 mm 80.2 in
Wheelbase 2360 mm 92.9 in
Track front/rear 1486 mm 58.5 in
Width between wheel boxes 925 mm 36.4 in
Turning circle 12.65 m 41 ft 6 in
V8 Models
Hardtop/station and county 4599 mm 181 in
Overall width 1790 mm 70.5 in
Overall height -
Non Japanese specification 2035 mm 80.1 in
Japanese specification 2060 mm 81.1 in
Wheelbase 2794 mm 110 in
Track front/rear 1486 mm 58.5 in
Width between wheel boxes
High capacity pick-up 1090 mm 43 in
All other models 925 mm 36.4 in
Item Metric Imperial
Overall length 5132 mm 202 in
Overall width 1790 mm 70.5 in
Overall height 2035 mm 80.1 in
Wheelbase 3266 mm 127 in
Track front/rear 1486 mm 58.5 in
Width between wheel boxes 1090 mm 43 in
Item Metric Imperial
Overall length 4072 mm 160.5 in
Overall width 1790 mm 70.5 in
Overall height 2037 mm 80.2 in
Wheelbase 2360 mm 92.9 in
Track front/rear 1486 mm 58.5 in
Width between wheel boxes 925 mm 36.4 in
Turning circle 12.65 m 41 ft 6 in
Health and Safety Precautions
Introduction
Modern vehicles contain many materials and liquids which if not handled with care can be hazardous to both personal
health and the environment. Also, many of the procedures associated with vehicle maintenance and repair involve
physical hazards or other risks to health.
This subsection lists some of these hazardous operations and the materials and equipment associated with them.
Precautions necessary to avoid these hazards are identified.
The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with
health and safety in mind.
Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be
consulted.
Acids and Alkalis
For example - alkalis such as caustic soda used in cleaning materials; acids such as sulphuric acid used in batteries.
Both alkalis and acids are irritant and corrosive to the skin, eyes, nose and throat. They cause burns and can destroy
ordinary protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not
breath mists.
Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
Highly flammable, explosive – observe No Smoking policy.
Used within the vehicle as safety restraints.
The inflator contains a high-energy propellant which, when ignited, produces a VERY HOT GAS (2500°C).
The gas inflator (generator) used in air bags is Sodium Azide. This material is hermetically sealed in each air bag
module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as
this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be
worn when dealing with the spillage.
After normal deployment, gloves and safety goggles should be worn during the handling process.
Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved
chemical waste site.
Following any direct contact with Sodium Azide:
z Wash affected areas thoroughly with water.
z SEEK IMMEDIATE MEDICAL ASSISTANCE.
Air Bags - Do's
Published: Feb 17, 2005
WARNING: Many liquids and other substances used in motor vehicles are poisonous and should
under no circumstances be consumed and should, as far as possible, be kept from contact with the skin.
These liquids and substances include acid, anti-freeze, brake fluid, fuel, windscreen washer additives,
lubricants, refrigerants and various adhesives.
Introduction
Modern vehicles contain many materials and liquids which if not handled with care can be hazardous to both personal
health and the environment. Also, many of the procedures associated with vehicle maintenance and repair involve
physical hazards or other risks to health.
This subsection lists some of these hazardous operations and the materials and equipment associated with them.
Precautions necessary to avoid these hazards are identified.
The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with
health and safety in mind.
Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be
consulted.
Acids and Alkalis
For example - alkalis such as caustic soda used in cleaning materials; acids such as sulphuric acid used in batteries.
Both alkalis and acids are irritant and corrosive to the skin, eyes, nose and throat. They cause burns and can destroy
ordinary protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not
breath mists.
Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
Highly flammable, explosive – observe No Smoking policy.
Used within the vehicle as safety restraints.
The inflator contains a high-energy propellant which, when ignited, produces a VERY HOT GAS (2500°C).
The gas inflator (generator) used in air bags is Sodium Azide. This material is hermetically sealed in each air bag
module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as
this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be
worn when dealing with the spillage.
After normal deployment, gloves and safety goggles should be worn during the handling process.
Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved
chemical waste site.
Following any direct contact with Sodium Azide:
z Wash affected areas thoroughly with water.
z SEEK IMMEDIATE MEDICAL ASSISTANCE.
Air Bags - Do's
Published: Feb 17, 2005
WARNING: Many liquids and other substances used in motor vehicles are poisonous and should
under no circumstances be consumed and should, as far as possible, be kept from contact with the skin.
These liquids and substances include acid, anti-freeze, brake fluid, fuel, windscreen washer additives,
lubricants, refrigerants and various adhesives.
z Do store modules in an upright position.
z Do keep modules dry.
z Do carry modules with the cover side pointing away from the body.
z Do place modules with their cover side upwards.
z Do carefully inspect modules for damage.
z Do stand to one side when connecting modules.
z Do make sure all test equipment is properly calibrated and maintained.
z Do wash hands after handling deployed air bags.
Air Bags - Do Not
z Do Not store highly flammable material together with modules or gas generators.
z Do Not store gas generators at temperatures exceeding 80°C.
z Do Not store modules upside down.
z Do Not attempt to open a gas generator housing.
z Do Not expose gas generators to open flame or sources of heat.
z Do Not place anything on top of a module cover.
z Do Not use damaged modules.
z Do Not touch a fired module or gas generator for at least 10 minutes after firing.
z Do Not use any electrical probes on the wiring circuit.
Air Suspension
Whenever work is being undertaken on the air suspension system, suitable eye protection must be worn.
Air Conditioning Refrigerant
Highly flammable, combustible – observe No Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and
goggles.
If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should
also be rinsed with an appropriate irrigation solution such as a solution of 9% Sodium Chloride and Purified Water.
DO NOT RUB THE EYES AND SEEK IMMEDIATE MEDICAL ATTENTION.
Air Conditioning Refrigerant
Do Not
z Do Not expose refrigerant bottles to sunlight or heat.
z Do Not expose refrigerant bottles to frost.
z Do Not drop refrigerant bottles.
z Do Not vent refrigerant to atmosphere under any circumstance.
z Do Not mix refrigerants.
Adhesives and Sealants
Many adhesives and sealants are highly flammable – OBSERVE NO SMOKING POLICY. These items, should be
stored in flameproof cabinets in No Smoking areas. Cleanliness and tidiness in use should be observed, for example
disposable paper covering benches. All adhesives and sealants should be dispensed from applicators where
possible; containers, including secondary containers, should be labelled appropriately.
Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the manufacturer's instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover
with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull skin tissue apart. Use
in well ventilated areas as vapors can cause irritation to the nose and eyes.
For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.
z Do keep modules dry.
z Do carry modules with the cover side pointing away from the body.
z Do place modules with their cover side upwards.
z Do carefully inspect modules for damage.
z Do stand to one side when connecting modules.
z Do make sure all test equipment is properly calibrated and maintained.
z Do wash hands after handling deployed air bags.
Air Bags - Do Not
z Do Not store highly flammable material together with modules or gas generators.
z Do Not store gas generators at temperatures exceeding 80°C.
z Do Not store modules upside down.
z Do Not attempt to open a gas generator housing.
z Do Not expose gas generators to open flame or sources of heat.
z Do Not place anything on top of a module cover.
z Do Not use damaged modules.
z Do Not touch a fired module or gas generator for at least 10 minutes after firing.
z Do Not use any electrical probes on the wiring circuit.
Air Suspension
Whenever work is being undertaken on the air suspension system, suitable eye protection must be worn.
Air Conditioning Refrigerant
Highly flammable, combustible – observe No Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and
goggles.
If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should
also be rinsed with an appropriate irrigation solution such as a solution of 9% Sodium Chloride and Purified Water.
DO NOT RUB THE EYES AND SEEK IMMEDIATE MEDICAL ATTENTION.
Air Conditioning Refrigerant
Do Not
z Do Not expose refrigerant bottles to sunlight or heat.
z Do Not expose refrigerant bottles to frost.
z Do Not drop refrigerant bottles.
z Do Not vent refrigerant to atmosphere under any circumstance.
z Do Not mix refrigerants.
Adhesives and Sealants
Many adhesives and sealants are highly flammable – OBSERVE NO SMOKING POLICY. These items, should be
stored in flameproof cabinets in No Smoking areas. Cleanliness and tidiness in use should be observed, for example
disposable paper covering benches. All adhesives and sealants should be dispensed from applicators where
possible; containers, including secondary containers, should be labelled appropriately.
Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the manufacturer's instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover
with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull skin tissue apart. Use
in well ventilated areas as vapors can cause irritation to the nose and eyes.
For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.
Solvent-based Adhesives/Sealers - See Solvents
Follow manufacturers instructions.
Water-based Adhesives/Sealers
Those based on polymer emulsions and rubber/latex may contain small amounts of volatile, toxic and harmful
chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the
inhalation of toxic fumes.
Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate
extraction.
Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-
based
Mixing should be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released.
Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful
chemicals through the skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact.
Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin-based Adhesives
Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity
reactions can occur.
Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the
nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to
vapour concentrations may result in adverse health effects.
Prolonged contact with the skin may lead to skin irritation and in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage.
Any spraying should preferably be carried out in ventilated booths which incorporate facilities for removing vapors
and spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory protection.
Antifreeze
May be flammable when undiluted.
Vapors may be given off from coolant antifreeze when heated. Avoid breathing these vapors.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be fatal;
SEEK IMMEDIATE MEDICAL ATTENTION.
Battery Acids
See also Alkalis and Acids.
Gases released during battery charging are explosive. Always remove the battery from the vehicle prior to charging.
Never use naked flames or allow sparks near charging or recently charged batteries. NEVER add acid to a battery,
the chemical reaction produced will be violent and explosive. In cases of eye contact, wash affected area with
Follow manufacturers instructions.
Water-based Adhesives/Sealers
Those based on polymer emulsions and rubber/latex may contain small amounts of volatile, toxic and harmful
chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the
inhalation of toxic fumes.
Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate
extraction.
Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-
based
Mixing should be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released.
Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful
chemicals through the skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact.
Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin-based Adhesives
Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity
reactions can occur.
Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the
nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to
vapour concentrations may result in adverse health effects.
Prolonged contact with the skin may lead to skin irritation and in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage.
Any spraying should preferably be carried out in ventilated booths which incorporate facilities for removing vapors
and spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory protection.
Antifreeze
May be flammable when undiluted.
Vapors may be given off from coolant antifreeze when heated. Avoid breathing these vapors.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be fatal;
SEEK IMMEDIATE MEDICAL ATTENTION.
Battery Acids
See also Alkalis and Acids.
Gases released during battery charging are explosive. Always remove the battery from the vehicle prior to charging.
Never use naked flames or allow sparks near charging or recently charged batteries. NEVER add acid to a battery,
the chemical reaction produced will be violent and explosive. In cases of eye contact, wash affected area with
copious amounts of water and SEEK IMMEDIATE MEDICAL ATTENTION.
Make sure there is adequate ventilation during battery charging, observe NO SMOKING POLICY.
Brake Pads and Linings
Always fit the correct grade and specification of brake pads and linings. When renewing pads and linings, always
replace as complete axle sets.
Brake and Clutch Fluid
Splashes to the skin and eyes are irritating and in the long term can be damaging, avoid prolonged skin contact. In
cases of eye contact, wash affected area with copious amounts of water and SEEK IMMEDIATE MEDICAL
ATTENTION.
Chemical Materials
All chemical materials should always be used with caution and stored and handled with care. They may be toxic,
harmful, corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent;
cumulative; superficial; life threatening; or may reduce life expectancy.
Chemical Materials - Do's
z Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in
any accompanying leaflets, posters or other instructions. Material health and safety data sheets can be
obtained from manufacturers.
z Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily
soiled clothing and have it cleaned.
z Do organise work practices and protective clothing to avoid soiling of the skin and eyes.
z Do avoid breathing vapors, aerosols, dusts or fumes; inadequate container labelling; fire and explosion
hazards.
z Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical
materials.
z Do keep work areas clean, uncluttered and free of spills.
z Do store chemical materials according to national and local regulations.
z Do keep chemical materials out of the reach of children.
Chemical Materials - Do Not
z Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form other
toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together.
z Do Not spray chemical materials, particularly those based on solvents, in confined spaces, for example when
people are inside a vehicle.
z Do Not apply heat or flame to chemical materials except under the manufacturers instructions. Some are
highly flammable and some may release toxic or harmful fumes.
z Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations.
Some fumes are heavier than air and will accumulate in confined areas such as pits.
z Do Not transfer chemical materials to unlabelled containers.
z Do Not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin and
may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities.
z Do Not use emptied containers for other materials except when they have been cleaned under supervised
conditions.
z Do Not sniff or smell chemical materials, even brief exposure to high concentrations of fumes can be toxic or
harmful.
Corrosion Protection Materials
Some corrosion protection materials are highly flammable – observe NO SMOKING POLICY.
These materials are varied and the manufacturers instructions must always be followed. The materials may contain
solvents, resins or petroleum products. Skin and eye contact should be avoided. They should only be sprayed in
conditions of adequate ventilation and not in confined spaces.
Make sure there is adequate ventilation during battery charging, observe NO SMOKING POLICY.
Brake Pads and Linings
Always fit the correct grade and specification of brake pads and linings. When renewing pads and linings, always
replace as complete axle sets.
Brake and Clutch Fluid
Splashes to the skin and eyes are irritating and in the long term can be damaging, avoid prolonged skin contact. In
cases of eye contact, wash affected area with copious amounts of water and SEEK IMMEDIATE MEDICAL
ATTENTION.
Chemical Materials
All chemical materials should always be used with caution and stored and handled with care. They may be toxic,
harmful, corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent;
cumulative; superficial; life threatening; or may reduce life expectancy.
Chemical Materials - Do's
z Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in
any accompanying leaflets, posters or other instructions. Material health and safety data sheets can be
obtained from manufacturers.
z Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily
soiled clothing and have it cleaned.
z Do organise work practices and protective clothing to avoid soiling of the skin and eyes.
z Do avoid breathing vapors, aerosols, dusts or fumes; inadequate container labelling; fire and explosion
hazards.
z Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical
materials.
z Do keep work areas clean, uncluttered and free of spills.
z Do store chemical materials according to national and local regulations.
z Do keep chemical materials out of the reach of children.
Chemical Materials - Do Not
z Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form other
toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together.
z Do Not spray chemical materials, particularly those based on solvents, in confined spaces, for example when
people are inside a vehicle.
z Do Not apply heat or flame to chemical materials except under the manufacturers instructions. Some are
highly flammable and some may release toxic or harmful fumes.
z Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations.
Some fumes are heavier than air and will accumulate in confined areas such as pits.
z Do Not transfer chemical materials to unlabelled containers.
z Do Not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin and
may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities.
z Do Not use emptied containers for other materials except when they have been cleaned under supervised
conditions.
z Do Not sniff or smell chemical materials, even brief exposure to high concentrations of fumes can be toxic or
harmful.
Corrosion Protection Materials
Some corrosion protection materials are highly flammable – observe NO SMOKING POLICY.
These materials are varied and the manufacturers instructions must always be followed. The materials may contain
solvents, resins or petroleum products. Skin and eye contact should be avoided. They should only be sprayed in
conditions of adequate ventilation and not in confined spaces.
Dust
Dust or powder produced during repair operations may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is
inadequate.
Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.
Electrical Equipment
Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good
condition.
Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should
be labelled and preferably removed from the work station.
Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged. If using
cable reel extension equipment, ALWAYS ensure that the cable is fully unwound from the reel.
Make sure that electrical equipment and flexes do not come into contact with water.
Make sure that electrical equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.
Make sure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.
Make sure that the designated electrical workers are trained in basic First Aid.
In cases of electrocution:
z Switch off the power supply before approaching the victim.
z If this is not possible, DO NOT TOUCH THE VICTIM but push or drag the person from the source of electricity
using dry, non-conductive material.
z Commence resuscitation if trained to do so.
z SEEK IMMEDIATE MEDICAL ATTENTION.
Exhaust Fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides,
aldehydes, lead and aromatic hydrocarbons. Engines should be run only under conditions of adequate exhaust
extraction or general ventilation and not in confined spaces.
Gasoline (Petrol) engine
There may not be adequate warning of odour or of irritation before toxic or harmful effects arise. These may be
immediate or delayed.
Gas Oil (Diesel engine)
Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.
Fibre Insulation
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical
effect.
Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the
use of gloves.
Fire
Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or
harmful fumes if burnt; others such as fluoroelastomers when burnt or damaged by excessive heat can break down
and produce highly corrosive hydrofluoric acid - See Fluoroelastomers.
Dust or powder produced during repair operations may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is
inadequate.
Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.
Electrical Equipment
Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good
condition.
Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should
be labelled and preferably removed from the work station.
Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged. If using
cable reel extension equipment, ALWAYS ensure that the cable is fully unwound from the reel.
Make sure that electrical equipment and flexes do not come into contact with water.
Make sure that electrical equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.
Make sure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.
Make sure that the designated electrical workers are trained in basic First Aid.
In cases of electrocution:
z Switch off the power supply before approaching the victim.
z If this is not possible, DO NOT TOUCH THE VICTIM but push or drag the person from the source of electricity
using dry, non-conductive material.
z Commence resuscitation if trained to do so.
z SEEK IMMEDIATE MEDICAL ATTENTION.
Exhaust Fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides,
aldehydes, lead and aromatic hydrocarbons. Engines should be run only under conditions of adequate exhaust
extraction or general ventilation and not in confined spaces.
Gasoline (Petrol) engine
There may not be adequate warning of odour or of irritation before toxic or harmful effects arise. These may be
immediate or delayed.
Gas Oil (Diesel engine)
Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.
Fibre Insulation
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical
effect.
Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the
use of gloves.
Fire
Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or
harmful fumes if burnt; others such as fluoroelastomers when burnt or damaged by excessive heat can break down
and produce highly corrosive hydrofluoric acid - See Fluoroelastomers.
Should any material be in a burnt or overheated condition, handle with extreme caution and wear protective clothing
when handling such items. Dispose of such material in accordance with local regulations.
Decontaminate and dispose of protective clothing immediately after use.
Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical
equipment or welding processes.
Make sure, before using electrical or welding equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid
procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place affected area in cool to cold water.
Individuals affected by inhalation of gases and fumes should be removed to fresh air immediately. If effects persist,
consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do not
induce vomiting unless this action is indicated on the label.
Fluoroelastomers (Synthetic Rubber)
Many 'O' rings, seals, hoses, flexible pipes and other similar which appear to be manufactured from natural rubber
are, in fact, made of synthetic materials called Fluoroelastomers.
Under normal operating conditions, these materials are safe and do not constitute a health hazard. However, if the
materials are damaged by burning or exposure to excessive heat, they can break down and produce highly corrosive
hydrofluoric acid.
Foams - Polyurethane
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases
should not work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and
respiratory protection. Do not remove the respirator immediately after spraying, wait until the vapour/mists have
cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked
flames or the use of electrical equipment during foaming operations and until vapors/mists have cleared should not
be allowed. Any heat cutting of cured foams or partially cured foams should be carried out in areas having suitable
fume extraction equipment.
WARNING: Contact with hydrofluoric acid can cause serious burns on contact with the skin. If skin
contact does occur, carry out the following steps immediately: Remove any contaminated clothing. SEEK
IMMEDIATE MEDICAL ATTENTION Irrigate affected area of skin with copious amounts of cold water or
limewater for 15 to 60 minutes.
when handling such items. Dispose of such material in accordance with local regulations.
Decontaminate and dispose of protective clothing immediately after use.
Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical
equipment or welding processes.
Make sure, before using electrical or welding equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid
procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place affected area in cool to cold water.
Individuals affected by inhalation of gases and fumes should be removed to fresh air immediately. If effects persist,
consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do not
induce vomiting unless this action is indicated on the label.
Fluoroelastomers (Synthetic Rubber)
Many 'O' rings, seals, hoses, flexible pipes and other similar which appear to be manufactured from natural rubber
are, in fact, made of synthetic materials called Fluoroelastomers.
Under normal operating conditions, these materials are safe and do not constitute a health hazard. However, if the
materials are damaged by burning or exposure to excessive heat, they can break down and produce highly corrosive
hydrofluoric acid.
Foams - Polyurethane
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases
should not work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and
respiratory protection. Do not remove the respirator immediately after spraying, wait until the vapour/mists have
cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked
flames or the use of electrical equipment during foaming operations and until vapors/mists have cleared should not
be allowed. Any heat cutting of cured foams or partially cured foams should be carried out in areas having suitable
fume extraction equipment.
WARNING: Contact with hydrofluoric acid can cause serious burns on contact with the skin. If skin
contact does occur, carry out the following steps immediately: Remove any contaminated clothing. SEEK
IMMEDIATE MEDICAL ATTENTION Irrigate affected area of skin with copious amounts of cold water or
limewater for 15 to 60 minutes.
Fuels
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.
Gasoline (Petrol)
Highly flammable - OBSERVE NO SMOKING POLICY.
Swallowing gasoline (petrol) can result in mouth and throat irritation and absorption from the stomach can result in
drowsiness and unconsciousness. Small amounts can be fatal to children. Inhalation into the lungs, through vomiting,
is a very serious hazard.
Gasoline (petrol) dries the skin and can cause irritation and prolonged or repeated contact may cause dermatitis; if it
is allowed to enter the eyes, it will cause severe smarting. Wash affected area with copious amounts of water and
SEEK IMMEDIATE MEDICAL ATTENTION.
Gasoline (petrol) may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentration
of vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache,
depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.
Make sure there is adequate ventilation when handling and using gasoline (petrol). Great care must be taken to avoid
the serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline (petrol) storage tanks.
Gasoline (petrol) should not be used as a cleaning agent. It must not be siphoned by mouth.
Gas-oil (Diesel Fuel)
Combustible.
Prolonged skin contact with high boiling point gas oils (diesel fuel) may cause serious skin disorders including skin
cancer.
Inhalation into the lungs will cause internal bleeding - SEEK IMMEDIATE MEDICAL ATTENTION.
If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable - OBSERVE NO SMOKING POLICY.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid
aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from
kerosene at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and
make sure there is adequate ventilation.
If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.
Gas Cylinders
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 138 bar
(13800 kPa) (2000 lbf/in²) and great care should be taken in handling these cylinders to avoid mechanical damage to
them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate
markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow or direct sunlight. Fuel
gases, for example acetylene and propane should not be stored in close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines and also to avoid sources of ignition.
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.
Gasoline (Petrol)
Highly flammable - OBSERVE NO SMOKING POLICY.
Swallowing gasoline (petrol) can result in mouth and throat irritation and absorption from the stomach can result in
drowsiness and unconsciousness. Small amounts can be fatal to children. Inhalation into the lungs, through vomiting,
is a very serious hazard.
Gasoline (petrol) dries the skin and can cause irritation and prolonged or repeated contact may cause dermatitis; if it
is allowed to enter the eyes, it will cause severe smarting. Wash affected area with copious amounts of water and
SEEK IMMEDIATE MEDICAL ATTENTION.
Gasoline (petrol) may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentration
of vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache,
depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.
Make sure there is adequate ventilation when handling and using gasoline (petrol). Great care must be taken to avoid
the serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline (petrol) storage tanks.
Gasoline (petrol) should not be used as a cleaning agent. It must not be siphoned by mouth.
Gas-oil (Diesel Fuel)
Combustible.
Prolonged skin contact with high boiling point gas oils (diesel fuel) may cause serious skin disorders including skin
cancer.
Inhalation into the lungs will cause internal bleeding - SEEK IMMEDIATE MEDICAL ATTENTION.
If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable - OBSERVE NO SMOKING POLICY.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid
aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from
kerosene at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and
make sure there is adequate ventilation.
If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.
Gas Cylinders
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 138 bar
(13800 kPa) (2000 lbf/in²) and great care should be taken in handling these cylinders to avoid mechanical damage to
them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate
markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow or direct sunlight. Fuel
gases, for example acetylene and propane should not be stored in close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines and also to avoid sources of ignition.
Only trained personnel should undertake work involving gas cylinders.
General Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used
where required.
Never use tools or equipment for any purpose other than that for which they were designed. Never overload
equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not
always immediately apparent and may result in a fatal failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A
damaged grinding wheel can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment or using spraying equipment.
Make sure there is adequate ventilation to control dusts, mists and fumes.
High Pressure Air, Lubrication and Oil Test Equipment
Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.
Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the
underlying tissue and cause serious injury.
Jacking
Always refer to the Jacking and Lifting section of this manual prior to raising the vehicle off the ground.
When vehicle is to be raised by means of a jack, ensure that it is standing on level ground, that parking brake is
applied and wheels are chocked. ALWAYS use the recommended jacking points and ensure that vehicle jack has
sufficient load capacity for the weight of the vehicle.
Ensure that hoists have sufficient load capacity for the weight of the vehicle.
Legal Aspects
There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment
in a workshop.
For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the
many health and safety laws and regulations within their country, published by both national and local authorities.
Lubricants and Greases
Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes
and skin.
Used Engine Oil
Prolonged and repeated contact with engine oil will result in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
Health Protection Precautions
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle
on safety stands.
General Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used
where required.
Never use tools or equipment for any purpose other than that for which they were designed. Never overload
equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not
always immediately apparent and may result in a fatal failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A
damaged grinding wheel can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment or using spraying equipment.
Make sure there is adequate ventilation to control dusts, mists and fumes.
High Pressure Air, Lubrication and Oil Test Equipment
Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.
Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the
underlying tissue and cause serious injury.
Jacking
Always refer to the Jacking and Lifting section of this manual prior to raising the vehicle off the ground.
When vehicle is to be raised by means of a jack, ensure that it is standing on level ground, that parking brake is
applied and wheels are chocked. ALWAYS use the recommended jacking points and ensure that vehicle jack has
sufficient load capacity for the weight of the vehicle.
Ensure that hoists have sufficient load capacity for the weight of the vehicle.
Legal Aspects
There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment
in a workshop.
For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the
many health and safety laws and regulations within their country, published by both national and local authorities.
Lubricants and Greases
Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes
and skin.
Used Engine Oil
Prolonged and repeated contact with engine oil will result in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
Health Protection Precautions
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle
on safety stands.
z Avoid prolonged and repeated contact with oils, particularly used engine oils.
z Wear protective clothing, including impervious gloves where practicable.
z Do not put oily rags into pockets.
z Avoid contaminating clothes, particularly underpants, with oil.
z Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.
z First Aid treatment should be obtained immediately for open cuts and wounds.
z Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
z Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help).
Preparations containing lanoline replace the natural skin oils which have been removed.
z Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
z If skin disorders develop, obtain medical advice without delay.
z Where practicable, degrease components prior to handling.
z Where there is a risk of eye contact, eye protection should be worn, for example chemical goggles or face
shields; in addition an eye wash facility should be provided.
Environmental Precautions
This section provides general information which can help to reduce the environmental impacts from the activities
carried out in workshops.
Emissions to air
Many of the activities that are carried out in workshops emit gases and fumes which can contribute to global warming,
depletion of the ozone layer and/or the formation of photochemical smog at ground level. By considering how the
workshop activities are carried out, these gases and fumes can be minimised, thus reducing the impact on the
environment.
Exhaust fumes
Running car engines is an essential part of workshop activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines are running and the position of the vehicle should be carefully
considered at all times, to reduce the release of poisonous gases and minimise the inconvenience to people living
nearby.
Solvents
Some of the cleaning agents used are solvent based and will evaporate rapidly to atmosphere if used carelessly, or if
containers are left unsealed. All containers must be firmly closed when not required and solvent should be used
sparingly. Wherever possible, solvents having a low toxicity and flammability should be selected. Always follow the
instructions supplied by the solvent manufacturer. Similarly, many paints are solvent based and the spray should be
used in such a way as to reduce emissions to a minimum.
Refrigerant
It is illegal to release any refrigerant into the atmosphere. Discharge and replacement of these materials from air
conditioning units should only be carried out using the appropriate equipment.
Discharges to water
Most workshops will have two systems for discharging waste water - storm drains and foul drains. Storm drains
should only receive clean water i.e. rainwater. Foul drains will accept many of the normal waste water i.e. washing
water, detergents and domestic type waste BUT NOT oil, petrol, solvent, acids, hydraulic fluid, antifreeze and similar
fluids. If in doubt, always consult the local authority or water company.
Spillages
Every precaution must be taken to prevent spillage of oil, fuel, solvents etc., reaching the drains. All handling of such
materials must take place well away from drains and preferably in an area with a suitable containing wall to prevent
discharge into drains or watercourses. If a spillage occurs, it must be soaked up immediately using a spill kit where
provided.
Checklist
z Wear protective clothing, including impervious gloves where practicable.
z Do not put oily rags into pockets.
z Avoid contaminating clothes, particularly underpants, with oil.
z Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.
z First Aid treatment should be obtained immediately for open cuts and wounds.
z Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
z Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help).
Preparations containing lanoline replace the natural skin oils which have been removed.
z Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
z If skin disorders develop, obtain medical advice without delay.
z Where practicable, degrease components prior to handling.
z Where there is a risk of eye contact, eye protection should be worn, for example chemical goggles or face
shields; in addition an eye wash facility should be provided.
Environmental Precautions
This section provides general information which can help to reduce the environmental impacts from the activities
carried out in workshops.
Emissions to air
Many of the activities that are carried out in workshops emit gases and fumes which can contribute to global warming,
depletion of the ozone layer and/or the formation of photochemical smog at ground level. By considering how the
workshop activities are carried out, these gases and fumes can be minimised, thus reducing the impact on the
environment.
Exhaust fumes
Running car engines is an essential part of workshop activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines are running and the position of the vehicle should be carefully
considered at all times, to reduce the release of poisonous gases and minimise the inconvenience to people living
nearby.
Solvents
Some of the cleaning agents used are solvent based and will evaporate rapidly to atmosphere if used carelessly, or if
containers are left unsealed. All containers must be firmly closed when not required and solvent should be used
sparingly. Wherever possible, solvents having a low toxicity and flammability should be selected. Always follow the
instructions supplied by the solvent manufacturer. Similarly, many paints are solvent based and the spray should be
used in such a way as to reduce emissions to a minimum.
Refrigerant
It is illegal to release any refrigerant into the atmosphere. Discharge and replacement of these materials from air
conditioning units should only be carried out using the appropriate equipment.
Discharges to water
Most workshops will have two systems for discharging waste water - storm drains and foul drains. Storm drains
should only receive clean water i.e. rainwater. Foul drains will accept many of the normal waste water i.e. washing
water, detergents and domestic type waste BUT NOT oil, petrol, solvent, acids, hydraulic fluid, antifreeze and similar
fluids. If in doubt, always consult the local authority or water company.
Spillages
Every precaution must be taken to prevent spillage of oil, fuel, solvents etc., reaching the drains. All handling of such
materials must take place well away from drains and preferably in an area with a suitable containing wall to prevent
discharge into drains or watercourses. If a spillage occurs, it must be soaked up immediately using a spill kit where
provided.
Checklist
Spillage prevention:
z Store liquids in a secure area.
z Make sure that taps on liquid containers are secure and cannot be accidentally turned on.
z Protect bulk storage tanks from vandalism by locking the valves.
z Transfer liquids from one container to another in an area away from open drains.
z Ensure lids are replaced securely on containers.
z Have spill kits available near to points of storage and liquid handling areas.
Spill Kits
Special materials are available to absorb a number of different substances. They can be in granular form, ready to
use and are supplied in suitable containers. Disposal of used spill absorbing material is dealt with in Waste
management.
Land contamination
Oils, fuels and solvents etc. can contaminate any soil with which they come into contact. Such materials MUST never
be disposed of by pouring on to soil and every precaution must be taken to avoid spillage reaching soil. Waste
materials stored on open ground could either leak or have contaminating substances washed off them that would
contaminate the land. Always store these materials in suitable skips or similarly robust containers.
Legal compliance
Some sites may have a discharge consent for effluent discharge to the foul drain for a car wash etc. It is essential to
know the types of effluent which are allowed to be discharged into the drain and to check the results of any
monitoring carried out by the Water Company.
Where paint spraying operations are carried out it may be necessary to apply to the Local Authority for an air
emissions licence to operate the plant. If such a licence is necessary, additional precautions will be necessary to
comply with the requirements and the results of any air quality monitoring must be checked regularly.
Checklist
Always adhere to the following:
z Know what legal consents and licences apply to the operations.
z Check that the emissions and discharges comply with legal requirements.
Waste Management
Pollution can be reduced by careful handling, storage and disposal of all waste materials that occur on sites.
Legislation makes it illegal to dispose of waste materials other than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know what the waste materials are but also to have the necessary
documentation and licences.
Handling and storage of waste
Ensure that waste materials are not poured down the drain or on to soil and are stored in such a way that they do not
escape on to land or soil.
z Store liquids in a secure area.
z Make sure that taps on liquid containers are secure and cannot be accidentally turned on.
z Protect bulk storage tanks from vandalism by locking the valves.
z Transfer liquids from one container to another in an area away from open drains.
z Ensure lids are replaced securely on containers.
z Have spill kits available near to points of storage and liquid handling areas.
Spill Kits
Special materials are available to absorb a number of different substances. They can be in granular form, ready to
use and are supplied in suitable containers. Disposal of used spill absorbing material is dealt with in Waste
management.
Land contamination
Oils, fuels and solvents etc. can contaminate any soil with which they come into contact. Such materials MUST never
be disposed of by pouring on to soil and every precaution must be taken to avoid spillage reaching soil. Waste
materials stored on open ground could either leak or have contaminating substances washed off them that would
contaminate the land. Always store these materials in suitable skips or similarly robust containers.
Legal compliance
Some sites may have a discharge consent for effluent discharge to the foul drain for a car wash etc. It is essential to
know the types of effluent which are allowed to be discharged into the drain and to check the results of any
monitoring carried out by the Water Company.
Where paint spraying operations are carried out it may be necessary to apply to the Local Authority for an air
emissions licence to operate the plant. If such a licence is necessary, additional precautions will be necessary to
comply with the requirements and the results of any air quality monitoring must be checked regularly.
Checklist
Always adhere to the following:
z Know what legal consents and licences apply to the operations.
z Check that the emissions and discharges comply with legal requirements.
Waste Management
Pollution can be reduced by careful handling, storage and disposal of all waste materials that occur on sites.
Legislation makes it illegal to dispose of waste materials other than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know what the waste materials are but also to have the necessary
documentation and licences.
Handling and storage of waste
Ensure that waste materials are not poured down the drain or on to soil and are stored in such a way that they do not
escape on to land or soil.
All waste must be segregated into individual types e.g. oils, metals, batteries, scrap components etc. This will prevent
any reaction between different materials and assist in disposal.
Disposal of waste
Dispose of waste in accordance with the following guidelines:
z Fuel, hydraulic fluid, anti-freeze and oil: Keep separate and dispose of to specialist contractors.
z Refrigerant: Collect in specialist equipment and reuse.
z Detergents: Safe to pour down the foul drain if diluted.
z Paint, thinners: Keep separate and dispose of to specialist contractor.
z Components: Return to supplier for refurbishment or disassemble and reuse any suitable parts. Dispose of
remainder in ordinary waste.
z Small parts: Reuse any suitable parts, dispose of the remainder in ordinary waste.
z Metals: Can be sold if separate from general waste.
z Tyres: Keep separate and dispose of to specialist contractor. DO NOT attempt to dispose of tyres by burning.
z Components/materials containing asbestos: Keep separate and dispose of to specialist contractor.
z Oil and fuel wastes (e.g. rags, used spill kit material): Keep separate and dispose of to specialist
contractors.
z Air filters: Keep separate and dispose of to specialist contractors.
z Rubber/plastics: Dispose of in ordinary waste.
z Hoses: Dispose of in ordinary waste.
z Batteries: Keep separate and dispose of to specialist contractors.
z Air bags - DANGER EXPLOSIVES: Keep separate and dispose of to specialist contractors.
z Electrical components: Return to supplier for refurbishment or disassemble and reuse any suitable
components. Dispose of remainder in ordinary waste.
z Catalytic converters: May be sold if kept separate from general waste.
z Packaging: Compact/recycle as much as possible and dispose of in ordinary waste.
z Office/paper waste: Recycle paper and toner and ink cartridges, dispose of remainder in ordinary waste.
Noise
Car alarm testing, panel beating, running engines, using air tools etc. are operations which invariably produce a large
amount of noise. The location of such activities and also the time of day must be carefully considered having regard
to the proximity of houses schools etc.
Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear
protection must be worn.
Solder
Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals
any reaction between different materials and assist in disposal.
Disposal of waste
Dispose of waste in accordance with the following guidelines:
z Fuel, hydraulic fluid, anti-freeze and oil: Keep separate and dispose of to specialist contractors.
z Refrigerant: Collect in specialist equipment and reuse.
z Detergents: Safe to pour down the foul drain if diluted.
z Paint, thinners: Keep separate and dispose of to specialist contractor.
z Components: Return to supplier for refurbishment or disassemble and reuse any suitable parts. Dispose of
remainder in ordinary waste.
z Small parts: Reuse any suitable parts, dispose of the remainder in ordinary waste.
z Metals: Can be sold if separate from general waste.
z Tyres: Keep separate and dispose of to specialist contractor. DO NOT attempt to dispose of tyres by burning.
z Components/materials containing asbestos: Keep separate and dispose of to specialist contractor.
z Oil and fuel wastes (e.g. rags, used spill kit material): Keep separate and dispose of to specialist
contractors.
z Air filters: Keep separate and dispose of to specialist contractors.
z Rubber/plastics: Dispose of in ordinary waste.
z Hoses: Dispose of in ordinary waste.
z Batteries: Keep separate and dispose of to specialist contractors.
z Air bags - DANGER EXPLOSIVES: Keep separate and dispose of to specialist contractors.
z Electrical components: Return to supplier for refurbishment or disassemble and reuse any suitable
components. Dispose of remainder in ordinary waste.
z Catalytic converters: May be sold if kept separate from general waste.
z Packaging: Compact/recycle as much as possible and dispose of in ordinary waste.
z Office/paper waste: Recycle paper and toner and ink cartridges, dispose of remainder in ordinary waste.
Noise
Car alarm testing, panel beating, running engines, using air tools etc. are operations which invariably produce a large
amount of noise. The location of such activities and also the time of day must be carefully considered having regard
to the proximity of houses schools etc.
Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear
protection must be worn.
Solder
Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals
(normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is
used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with grease, and inhalation of these
should be avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which
can give toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from
clothing.
Solvents
For example acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact.
Some can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness,
headaches and, in the worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not
be adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Make sure there is good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers
tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, for example paints, adhesives, and metal coatings, use extraction
ventilation or personal respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturers instructions.
Suspended Loads
There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or
raised load, for example a suspended engine.
Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for
the job, in good condition and regularly maintained.
Viton
In common with many other manufacturers vehicles, some components installed to Land Rover vehicles have seals,
'O' rings or gaskets which contain a material known as 'Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. Although Viton is the most well
known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to
temperatures in excess of 400°C, the material will not burn, but will decompose, and one of the products formed is
hydrofluoric acid.
CAUTION: Never improvise lifting tackle.
used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with grease, and inhalation of these
should be avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which
can give toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from
clothing.
Solvents
For example acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact.
Some can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness,
headaches and, in the worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not
be adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Make sure there is good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers
tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, for example paints, adhesives, and metal coatings, use extraction
ventilation or personal respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturers instructions.
Suspended Loads
There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or
raised load, for example a suspended engine.
Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for
the job, in good condition and regularly maintained.
Viton
In common with many other manufacturers vehicles, some components installed to Land Rover vehicles have seals,
'O' rings or gaskets which contain a material known as 'Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. Although Viton is the most well
known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to
temperatures in excess of 400°C, the material will not burn, but will decompose, and one of the products formed is
hydrofluoric acid.
CAUTION: Never improvise lifting tackle.
This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system.
WHERE CASES OF SKIN CONTACT OCCUR, SEEK IMMEDIATE MEDICAL HELP.
O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky
substance.
DO NOT, under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-
ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the material
may be Viton or any fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the
commencement of work.
Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool
and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue
and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.
Welding
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.
Resistance Welding
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be
protected.
Arc Welding
This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and to
other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection
must be worn, and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING
as the arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may
result in blindness when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any
applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and
inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area
may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is
anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators
may be necessary.
Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of
these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright, and eye protection should be used, but the ultra-violet emission is much less than that from arc
welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,
particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.
CAUTION: Some of the components installed to the vehicle e.g. the interior cross beam and
underbonnet cross member are manufactured from magnesium alloy. On no account should any welding
operations be attempted on these components.
WHERE CASES OF SKIN CONTACT OCCUR, SEEK IMMEDIATE MEDICAL HELP.
O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky
substance.
DO NOT, under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-
ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the material
may be Viton or any fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the
commencement of work.
Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool
and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue
and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.
Welding
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.
Resistance Welding
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be
protected.
Arc Welding
This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and to
other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection
must be worn, and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING
as the arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may
result in blindness when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any
applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and
inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area
may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is
anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators
may be necessary.
Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of
these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright, and eye protection should be used, but the ultra-violet emission is much less than that from arc
welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,
particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.
CAUTION: Some of the components installed to the vehicle e.g. the interior cross beam and
underbonnet cross member are manufactured from magnesium alloy. On no account should any welding
operations be attempted on these components.
In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing
rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert
advice may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON
VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR STEAMING
OUT OF FUEL TANKS.
Warning Symbols on Vehicles
Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out
service or repair operations on the vehicle.
rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert
advice may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON
VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR STEAMING
OUT OF FUEL TANKS.
Warning Symbols on Vehicles
Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out
service or repair operations on the vehicle.
Special Tool Glossary
Service Tools
Special service tools have been developed to facilitate removal, dismantling and assembly of mechanical
components in a cost effective and time efficient manner. The use of such special tools also helps prevent the
potential for damage to components.
Some operations described in this manual cannot be carried out properly without the aid of the relevant service tools.
All orders and enquiries from the United Kingdom and European countries except Germany, Austria, Switzerland and
Spain and countries not in the following list should be sent direct to:
SPX UK Ltd.,
Genoa House,
Everdon Park,
Daventry,
Northants,
NN11 5YJ
England
Tel: 0044 (0) 1327 303467/303455
Fax: 0044 (0) 1327 706632
e-mail: spxsalesuk@servicesolutions.spx.com
Overseas orders for the following countries should be placed with the local distributor.
Germany, Austria and Switzerland
SPX Europe GMBH,
Porschestrasse 4,
63512 Hainburg,
Germany
Tel: 0049 61829590
Fax: 0049 6182959299
Spain
SPX Iberica SA,
C/Francisco Aritio,
Published: Feb 26, 2004
Service Tools
Special service tools have been developed to facilitate removal, dismantling and assembly of mechanical
components in a cost effective and time efficient manner. The use of such special tools also helps prevent the
potential for damage to components.
Some operations described in this manual cannot be carried out properly without the aid of the relevant service tools.
All orders and enquiries from the United Kingdom and European countries except Germany, Austria, Switzerland and
Spain and countries not in the following list should be sent direct to:
SPX UK Ltd.,
Genoa House,
Everdon Park,
Daventry,
Northants,
NN11 5YJ
England
Tel: 0044 (0) 1327 303467/303455
Fax: 0044 (0) 1327 706632
e-mail: spxsalesuk@servicesolutions.spx.com
Overseas orders for the following countries should be placed with the local distributor.
Germany, Austria and Switzerland
SPX Europe GMBH,
Porschestrasse 4,
63512 Hainburg,
Germany
Tel: 0049 61829590
Fax: 0049 6182959299
Spain
SPX Iberica SA,
C/Francisco Aritio,
Published: Feb 26, 2004
158 nave 72 (Nudo Oeste),
19004 Guadalajara,
Spain
Tel: 0034 949208381
Fax: 0034 949208327
North America
SPX Corporation
665, Eisenhower Drive,
Owatonna,
MN 55060,
USA
Tel: 0018 772979110
Fax: 0018 005787375
Australia
SPX Australia,
28, Clayton Road,
Notting Hill,
Victoria 3168,
Australia
Tel: 0061 00395446222
Fax: 0061 00395445222
e-mail: sales@spx.com.au
Japan and East Asia
Jatek Ltd.,
5 - 53, Minawacho 2-chome,
Kohoku-ku,
Yokohama,
Kanagawa 223-0051,
19004 Guadalajara,
Spain
Tel: 0034 949208381
Fax: 0034 949208327
North America
SPX Corporation
665, Eisenhower Drive,
Owatonna,
MN 55060,
USA
Tel: 0018 772979110
Fax: 0018 005787375
Australia
SPX Australia,
28, Clayton Road,
Notting Hill,
Victoria 3168,
Australia
Tel: 0061 00395446222
Fax: 0061 00395445222
e-mail: sales@spx.com.au
Japan and East Asia
Jatek Ltd.,
5 - 53, Minawacho 2-chome,
Kohoku-ku,
Yokohama,
Kanagawa 223-0051,
Japan
Tel: 0081 455627700
Fax: 0081 455627800
Tel: 0081 455627700
Fax: 0081 455627800